US2537126A - Coated sheet material and process for making the same - Google Patents

Coated sheet material and process for making the same Download PDF

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Publication number
US2537126A
US2537126A US44284A US4428448A US2537126A US 2537126 A US2537126 A US 2537126A US 44284 A US44284 A US 44284A US 4428448 A US4428448 A US 4428448A US 2537126 A US2537126 A US 2537126A
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US
United States
Prior art keywords
film
fibers
regions
web
fibrous web
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
US44284A
Inventor
Jr Carleton S Francis
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Akzo Nobel UK PLC
Original Assignee
American Viscose Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by American Viscose Corp filed Critical American Viscose Corp
Priority to US44284A priority Critical patent/US2537126A/en
Priority to FR999762D priority patent/FR999762A/en
Priority to BE492314D priority patent/BE492314A/xx
Priority to GB30054/49A priority patent/GB673129A/en
Application granted granted Critical
Publication of US2537126A publication Critical patent/US2537126A/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/007—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by mechanical or physical treatments
    • D06N3/0077—Embossing; Pressing of the surface; Tumbling and crumbling; Cracking; Cooling; Heating, e.g. mirror finish
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/0046—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by constructional aspects of the apparatus
    • B32B37/0053—Constructional details of laminating machines comprising rollers; Constructional features of the rollers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/10—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
    • B32B37/1027—Pressing using at least one press band
    • B32B37/1036—Pressing between one press band and a cylinder
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/16—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating
    • B32B37/20—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating involving the assembly of continuous webs only
    • B32B37/203—One or more of the layers being plastic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/02—2 layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/02—Coating on the layer surface on fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0223—Vinyl resin fibres
    • B32B2262/023—Aromatic vinyl resin, e.g. styrenic (co)polymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0223—Vinyl resin fibres
    • B32B2262/0238—Vinyl halide, e.g. PVC, PVDC, PVF, PVDF
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0246—Acrylic resin fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0253—Polyolefin fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/04—Cellulosic plastic fibres, e.g. rayon
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/06—Vegetal fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/08—Animal fibres, e.g. hair, wool, silk
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2270/00—Resin or rubber layer containing a blend of at least two different polymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B23/00—Layered products comprising a layer of cellulosic plastic substances, i.e. substances obtained by chemical modification of cellulose, e.g. cellulose ethers, cellulose esters, viscose
    • B32B23/10—Layered products comprising a layer of cellulosic plastic substances, i.e. substances obtained by chemical modification of cellulose, e.g. cellulose ethers, cellulose esters, viscose next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/732—Dimensional properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2437/00—Clothing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2451/00—Decorative or ornamental articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B25/00—Layered products comprising a layer of natural or synthetic rubber
    • B32B25/10—Layered products comprising a layer of natural or synthetic rubber next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2607/00—Walls, panels
    • B32B2607/02—Wall papers, wall coverings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/304—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/306—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl acetate or vinyl alcohol (co)polymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/34—Layered products comprising a layer of synthetic resin comprising polyamides
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/30—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/024—Woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/14—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by a layer differing constitutionally or physically in different parts, e.g. denser near its faces
    • B32B5/142—Variation across the area of the layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10—Methods of surface bonding and/or assembly therefor
    • Y10T156/1002—Methods of surface bonding and/or assembly therefor with permanent bending or reshaping or surface deformation of self sustaining lamina
    • Y10T156/1039—Surface deformation only of sandwich or lamina [e.g., embossed panels]
    • Y10T156/1041—Subsequent to lamination
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24479—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness
    • Y10T428/24521—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness with component conforming to contour of nonplanar surface
    • Y10T428/24554—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness with component conforming to contour of nonplanar surface including cellulosic or natural rubber component
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24479—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness
    • Y10T428/24595—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness and varying density
    • Y10T428/24603—Fiber containing component
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24802—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]

Definitions

  • This invention relates in general to coated sheet materials and to processes of making coated sheet materials. tion relates to coated sheet materials on which may be formed a depressed design, coated sheet materials having a depressed design, and to processes of makin said coated sheet materials.
  • Coated sheet materials heretofore produced are of several types.
  • the material comprises a backing or base supporting layer of a woven fabric such as flannel to one side of which a multiplicity of coatings of nitro cellulose lacquer have been applied.
  • This coated product may be smooth or may be embossed to provide a suitable decorative grain or other design.
  • the coatings are normally applied to the backing fabric as a solution of nitro cellulose in a volatile organic solvent.
  • the manufacture of this type of artificial leather requires numerous coating operations in order to cover the nap fibers which would otherwise protrude through the coating. Since the nitro cellulose solutionis applied directly to the fabric, some penetration ofthe nitro cellulose into the fabric takes place which is wasteful of the coating composition and tends to unduly stiffen the product. This procedure also requires the use of expensive solvent recovery equipment in order to operate economically.
  • the coating is applied to a backing or base supporting layer by calendering.
  • the coating material in paste-like form is applied to a calendering roll and from the roll the paste-like material is applied directly to the fabric.
  • the coating material is forced into the interstices in! the fabric requiring an excess amount of coating material and resulting in a relatively heavy coating 'on the fabric.
  • the backing or base supporting layer is of felt.
  • the coating solution is applied directly to the felt and after drying, the coating is given a decorative effect by pressingiprstamplng selected areas of the coating.
  • This product has all the disadvantages of the first mentioned type of product and in addition it is found that as the felt layer or backing has some resilience, the embossing effect does not remain permanently but gradually disappears as the felt' expands in the areas More particularly, this inven- Claims. (01. 1 54-106) provide coated fibrous 2 a sheet material in which may be formed a depressed design and which will retain the design permanently, which is economical'to produce and which is relatively free of coating material through the body of the fibrous material.
  • Another object of the invention is to provide coated fibrous sheet material having a depressed design which retains the design permanently, which is economical to produce and which is relatively free of coating material throughout the body of the fibrous material.
  • Another object of the invention is to provide an economical process for making coated fibrous sheet material in whicha depressed design may be formed and which will retain the design permanently, and which is relatively free ofcoating material throughout the body of thefibrousmaterial.
  • a further object of the invention is to provide an economical process for making coated fibrous sheet material having a depressed design which will. retain the design permanently, and which will be relatively free of coating material through the body of the fibrous material.
  • Figure 1 is a diagrammatical side elevational view of a form of apparatus suitable for carrying out a process and making products embodying this invention.
  • Figure 2 is a perspective view of a form 0 product embodying this invention.
  • Figure 3 is a cross-sectional view greatly enlarged of a form of product embodying this invention.
  • the present invention provides coated fibrous sheet material that is suitable to be used for upholstery, handbags, wall coverings, table covsheet material comprises at least one layer of a fiber bonded web to at least one surface of which a thin continuous film of thermoplastic organic material is adhered or bonded.
  • the fiber bonded 'web is characterized by some resilience and is compressible to less thickness.
  • the film bonded to the fiber bonded web may be given a decorative effect by pressing or stamping selected areas of the film -by a shaped or en-' areas of the film are depressed and the areas of the film that have not been pressed or stamped appear to be raised with respect to the other areas of the film and a decorative eflect like embossing is produced.
  • the regions ofthe fibrous web beneath the pressed or stamped areas of the film are compressed and are of greater density than the other regions of the fibrous web.
  • the fibers in the fibrous web in the regions of greate density are bonded together and the increased density of these regions and the embossed effect is retained.
  • the fiber bonded web used in this invention comprises fibers such as cotton, wood pulp, wool, silk, hemp, flax, hair, fur, or regenerated celluto forty (40%) percent, of heat activatable fibers for instance fibers of thermoplastic materials or thermosetting materials in a thermoplastic state referred to herein generally as thermoplastic.
  • materials such as polyvinyl chloride, polyvinylidene chloride, copolymers of vinylidene chloride and vinyl chloride, polystyrene, copolylose, and a minor proportion, of the order of ten mers of vinyl chloride and vinyl acetate, polyapplication of heat to bond fibers in the web.
  • thermoplastic fibers This activation of the thermoplastic fibers is such that the potentially adhesive properties of those fibers is not substantially decreased.
  • thermoplastic organicv material used in this invention is of thermoplastic resin, thermoplastic cellulosic material, thermosetting resin in a thermoplastic state or mixtures of thermoplastic and thermosetting resins in a thermoplastic state.
  • thermoplastic materials include, for example, polyvinyl chloride, copolymers of vinyl chloride and vinyl acetate, copolya backing sheet, the web and film may then be cooled and the backing sheet stripped oil, or the fibrous web and the film may be cooled after subsequent operations and the backing sheet stripped oif. Selected areas of the film are pressed or stamped with sufiicient pressure to form depressed areas in the film and to compress or densify the fibrous material in the regions beneath the stamped or pressed areas of the film.
  • the selected areas of the film may be pressed or stamped while the thermoplastic fibers in the fibrous web are adhesive or those fibers may be made adhesive directly after the stamping or pressing of the film.
  • the fibrous web is then allowed to cool to set the thermoplastic fibers while the fibers in the web in the regions beneath the stamped areas of the web are compressed together to bond the fibers in the web and to the film while the fibers in those regions are compressed.
  • Reference characters I and 2 indicate a pair of rollers between which a non-woven fibrous web 20 containing a minor proportion of thermoplastic fibers is fed from a card, garnet, or other fiber mixing and web forming device which is not shown.
  • the rollers I and 2 may be heated to activate the thermoplastic fibers to cause some bonding to take place to enable the web to be more easily handled during subsequent operations.
  • thermoplastic material 3 on a temporary backing sheet 4 is drawn from a roll -5 and is applied to the web, and the web and the film on the backing sheet are passed around a portion a of the heated drum 6.
  • the web and the film are mers of vinylidene chloride and vinyl chloride,
  • the film and the fibrous web 1 are subjected to heat sufficient to make the film and thermoplastic fibers in the web tacky or ad hesive without substantially altering their form.
  • the film and the fibrous web are uniformly pressed together to adherethe film to the fibrous web and particularly to adhere or bond thermoplastic fibers in the web to the film without completely compressing the fibrous web. Because of the afiinity between the material of the film and that of the thermoplastic fibers of the web when 7 they are made adhesive by the application of heat, a secure bond is formed between them, and the film and the thermoplastic fibers form an integral structure.
  • the film is supported on uniformly pressed against the drum with the backing sheet between the film and the drum by the continuous belt member I that passes over the guiding and tensiomng rollers 8, 9, l0, and H. Suitable means not shown are provided for rotating the drum and the rollers in the directions shown by the arrows.
  • the heat of the drum 6 is sufiicient to render the thermoplastic film and the thermoplastic fibers in the web tacky so that the film is bonded or adhered to the fibrous web by its own adhesiveness and that of the thermoplastic fibers in contact therewith and the film and thermoplastic fibers in contact therewith form an integral structure.
  • the pressure of the belt is firm but is not sufiicient to completely compress the fibrous web.
  • the fibrous web, film, and backing sheet are withdrawn from the heated drum and sent through the cooling chamber 12 which renders the film non-tacky.
  • the backing sheet is then stripped from the thermoplastic film by the stripping roller [3 and collected on the roll IS.
  • the film and the fibrous web are thereafter directed between the roller it that has projecting portions thereon in the form of a design and the supporting roller l5, where selected areas of the film are pressed or stamped by the projecting portions of the roller l4 and the regions of the fibrous web beneath the areas of the film that have been pressed or stamped are compressed.
  • the supporting roller I5 is heated to a temperature sufiicient to cause the thermoplastic fibers or particles in the fibrous web to become tacky without softening the film.
  • the fibrousweb is cooled by an air blast or the like shown at I! which renders the adhesive fibers nonadhesive and sets the bonded fibers in the compressed regisnsor the web.
  • thermoplastic film is afterwards collected on the roll it a
  • selected areas of the thermoplastic film may be' pressed or stamped through the backing sheet in which case the roller having theprojecting portions is positioned in advance of the cooling chamberr
  • Figure 2 of thedrawing shows a perspective view of the product embodying the presentina other fibers 26 and prevent the compressed regions from expanding due to their natural resilience which would otherwise flatten or remove.
  • thermoplastic fibers bonded to the film are integral with the film.
  • the thermoplastic fibers bonded to the other fibers and the film strengthen the fibrous web and prevent delamination.
  • an organisol in the form of a plaste applied to a temporary backing sheet may be used instead of using a film as the coating material in practicing this invention.
  • the organisol may comprise a powdered or finely divided thermoplastic resin such as one of the vinyl resins in a vehicle comprising a volatile or removable liquid that does not dissolve the resin and a minor proportion of a solvent for the resin.
  • the organisol is applied to the temporary backing sheet 4 in the form of a paste and dried so that the sheet maybe handled.
  • the resin particles flow together forming a film which is adhered as a film to the fibrous web.
  • Reference character 20 indicates the m non-woven fibrous bonded, web and "3 the film the film and the thermop a tic fibers in the fibrous web adhesive to adhere the film to the fibrous web without substantially altering the form of the film and thermoplastic fibers, bond fibers in'the fibrous web and bond thermoplastic fiberstothefilm.
  • I claim: 1. The method of making coated fibrous sheet material comprising adhering a. film of thermoplastic material to a surface of a compressible non-woven fibrous web having thermoplastic fibers therein by pressin the film and fibrous web I together and compressing the fibrous web only a portion of the limit to which it could be compressed while subjecting the fibrous web and film o to .heat sufiicient to render the film and therand bond thermoplastic fibers to the film.-
  • coated fibrous sheet material comprising adhering a film of thermos plastic material to a surface of a compressible non-woven fibrous web having a minor proportion of thermoplastic fibers therein by pressing the film and fibrous web together and compressing the fibrous web only a portion of the limit to which it could be compressed while subjecting the the compressed state.
  • coated fibrous sheet material having a depressed design therein that 5 will retain the design comprising depressing selected areas of a film that is adhered to a surface of a compressible non-woven fibrous web containing thermoplastic fibers and compressing the regions of the fibrous web beneath the selected areas of the film that are depressed while the thermoplastic fibers are in an adhesive state, and rendering the adhesive fibers in the region of the fibrous web beneath the depressed areas of the film non-adhesive while these regions are compressed to bond fibers in theseregions in the compressed state.
  • coated fib ous sheet material having a depressed design I rein that will retain the design comprising depressing compressible non-woven fibrous web containing a minor proportion of thermoplastic fibers and compressing the regions of the fibrous web beneath the selected areas of the film that are depressed, heating the thermoplastic fibers in the regions of the fibrous web beneath the areas of the film that are depressed to render the thermoplastic fibers adhesive while these regions are compressed, and cooling the adhesive fibers to render these fibers non-adhesive while these regions are compressed to bond fibers in these regions in the compressed state.
  • the method of making coated fibrous sheet material having a depressed design therein that will retain the design comprising depressing through the temporary backing sheet selected areas of a film on a temporary backing sheet that is adhered to a surface of a compressible non-.- woven fibrous web containing a minor proportion of thermoplastic fibers and compressing the regions of the fibrous web beneath the selected areas'of the film that are depressed, rendering the thermoplastic fibers in the regions of the fibrous webbeneath the areas of the film that are depressed adhesive while these regions are compressed, and rendering the adhesive fibers in the regions of the fibrous web beneath the depressed areas of the film non-adhesive while these regions are compressed to bond fibers in these regions in the compressed state.
  • Coated fibrous sheet material that may have a design pressed therein and the design retained comprising a thermoplastic film adhered to a surface of a compressible resilient non-woven fibrous fibrous web and film to heat suific'ient to render 15 web containing a minor proportion of thermoplastic fibers bonded to the film and other fibers, said web being relatively free or coating material throughout the body of the web and compressed to only a portion of the limit to which it can be compressed.
  • Coated fibrous sheet material that may have a design pressed therein and the design retained comprising a thermoplastic film adhered to a surface of a compressible resilient non-woven fibrous web containing thermoplastic fibers bonded-to the film and other fibers, said web being relatively free of coating material throughout the body of the web and compressed to only a portion of the limit to which it can be compressed.
  • a coated fibrous sheet material comprising a thermoplastic film having a depressed design therein adhered to a surface of a non-woven fibrous web containing a minor proportion of.
  • thermoplastic fibers bonded to the film and other fibers said web being relatively free of coating material throughout the body of the web having regions beneath the depressed areas of the film comprising the design, compressed and of greater density than other portions of the web and with fibers bonded'in the regions of greater density.
  • a coated fibrous sheet material comprising a thermoplastic film having a depressed design therein adhered to a surface of a non-woven fibrous web containing thermoplastic fibers bonded to the film and other fibers, said web being relatively free of'coating material throughout the body of the web having regions beneath the depressed areas of the film comprising the design, compressed and of greater density than other portions of the web and with fibers bonded in the regions of greater density.

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Description

Jan. 9, 1951 c. s. FRANCIS, JR 2,537,126
. COATED SHEET MATERIAL AND PRQCESS FOR MAKING THE- SAME Filed Aug. 14, 1948 INVENTOR. CARLE TON 6. FRANCI6,JR.
Patented Jan. 9, 1951 UNITED ST TES rATENroFFicE assuze a Y l COATED SHEET MATERIAL rnocnss FOR MAKINGTHE SAME Carleton S. Francis, Jr-, West Harwich, Mass., assignor to American Viscose Corporation, Wilmington, Del., a corporation, of Delaware Application August 14, 1948, Serial No. 44,284
1 This invention relates in general to coated sheet materials and to processes of making coated sheet materials. tion relates to coated sheet materials on which may be formed a depressed design, coated sheet materials having a depressed design, and to processes of makin said coated sheet materials.
Coated sheet materials heretofore produced are of several types. In one type the material comprises a backing or base supporting layer of a woven fabric such as flannel to one side of which a multiplicity of coatings of nitro cellulose lacquer have been applied. 'This coated product may be smooth or may be embossed to provide a suitable decorative grain or other design. The coatings are normally applied to the backing fabric as a solution of nitro cellulose in a volatile organic solvent. The manufacture of this type of artificial leather requires numerous coating operations in order to cover the nap fibers which would otherwise protrude through the coating. Since the nitro cellulose solutionis applied directly to the fabric, some penetration ofthe nitro cellulose into the fabric takes place which is wasteful of the coating composition and tends to unduly stiffen the product. This procedure also requires the use of expensive solvent recovery equipment in order to operate economically.
In another type of coated sheet material, the coating. is applied to a backing or base supporting layer by calendering. The coating material in paste-like form is applied to a calendering roll and from the roll the paste-like material is applied directly to the fabric. The coating material is forced into the interstices in! the fabric requiring an excess amount of coating material and resulting in a relatively heavy coating 'on the fabric.
In a further type of coated sheet material, the backing or base supporting layer is of felt. The coating solution is applied directly to the felt and after drying, the coating is given a decorative effect by pressingiprstamplng selected areas of the coating. This product has all the disadvantages of the first mentioned type of product and in addition it is found that as the felt layer or backing has some resilience, the embossing effect does not remain permanently but gradually disappears as the felt' expands in the areas More particularly, this inven- Claims. (01. 1 54-106) provide coated fibrous 2 a sheet material in which may be formed a depressed design and which will retain the design permanently, which is economical'to produce and which is relatively free of coating material through the body of the fibrous material.
Another object of the invention. is to provide coated fibrous sheet material having a depressed design which retains the design permanently, which is economical to produce and which is relatively free of coating material throughout the body of the fibrous material.
Another object of the invention is to provide an economical process for making coated fibrous sheet material in whicha depressed design may be formed and which will retain the design permanently, and which is relatively free ofcoating material throughout the body of thefibrousmaterial.
A further object of the invention is to provide an economical process for making coated fibrous sheet material having a depressed design which will. retain the design permanently, and which will be relatively free of coating material through the body of the fibrous material.
Other objects and advantages of the invention will be apparent from the following description and the accompanying drawing.
' In the drawing,
Figure 1 is a diagrammatical side elevational view of a form of apparatus suitable for carrying out a process and making products embodying this invention.
Figure 2 is a perspective view of a form 0 product embodying this invention.
Figure 3 is a cross-sectional view greatly enlarged of a form of product embodying this invention.
The present invention provides coated fibrous sheet material that is suitable to be used for upholstery, handbags, wall coverings, table covsheet material comprises at least one layer of a fiber bonded web to at least one surface of which a thin continuous film of thermoplastic organic material is adhered or bonded. The fiber bonded 'web is characterized by some resilience and is compressible to less thickness.
v graved plate or roller. The'pressed .or stamped Thefilm bonded to the fiber bonded web may be given a decorative effect by pressing or stamping selected areas of the film -by a shaped or en-' areas of the film are depressed and the areas of the film that have not been pressed or stamped appear to be raised with respect to the other areas of the film and a decorative eflect like embossing is produced. The regions ofthe fibrous web beneath the pressed or stamped areas of the film are compressed and are of greater density than the other regions of the fibrous web. The fibers in the fibrous web in the regions of greate density are bonded together and the increased density of these regions and the embossed effect is retained.
The fiber bonded web used in this invention comprises fibers such as cotton, wood pulp, wool, silk, hemp, flax, hair, fur, or regenerated celluto forty (40%) percent, of heat activatable fibers for instance fibers of thermoplastic materials or thermosetting materials in a thermoplastic state referred to herein generally as thermoplastic. materials such as polyvinyl chloride, polyvinylidene chloride, copolymers of vinylidene chloride and vinyl chloride, polystyrene, copolylose, and a minor proportion, of the order of ten mers of vinyl chloride and vinyl acetate, polyapplication of heat to bond fibers in the web.
This activation of the thermoplastic fibers is such that the potentially adhesive properties of those fibers is not substantially decreased.
The film of thermoplastic organicv material used in this invention is of thermoplastic resin, thermoplastic cellulosic material, thermosetting resin in a thermoplastic state or mixtures of thermoplastic and thermosetting resins in a thermoplastic state. Such materials are referred to herein generally as thermoplastic materials and include, for example, polyvinyl chloride, copolymers of vinyl chloride and vinyl acetate, copolya backing sheet, the web and film may then be cooled and the backing sheet stripped oil, or the fibrous web and the film may be cooled after subsequent operations and the backing sheet stripped oif. Selected areas of the film are pressed or stamped with sufiicient pressure to form depressed areas in the film and to compress or densify the fibrous material in the regions beneath the stamped or pressed areas of the film. The selected areas of the film may be pressed or stamped while the thermoplastic fibers in the fibrous web are adhesive or those fibers may be made adhesive directly after the stamping or pressing of the film. The fibrous web is then allowed to cool to set the thermoplastic fibers while the fibers in the web in the regions beneath the stamped areas of the web are compressed together to bond the fibers in the web and to the film while the fibers in those regions are compressed.
Referring to Figure 1 of the drawing the invention will be described in connection with a form of apparatus diagrammatically shown with which an embodiment of this invention may be carried out. Reference characters I and 2 indicate a pair of rollers between which a non-woven fibrous web 20 containing a minor proportion of thermoplastic fibers is fed from a card, garnet, or other fiber mixing and web forming device which is not shown. The rollers I and 2 may be heated to activate the thermoplastic fibers to cause some bonding to take place to enable the web to be more easily handled during subsequent operations. A
film of thermoplastic material 3 on a temporary backing sheet 4 is drawn from a roll -5 and is applied to the web, and the web and the film on the backing sheet are passed around a portion a of the heated drum 6. The web and the film are mers of vinylidene chloride and vinyl chloride,
the fibrous web. The film and the fibrous web 1 are subjected to heat sufficient to make the film and thermoplastic fibers in the web tacky or ad hesive without substantially altering their form.
The film and the fibrous web are uniformly pressed together to adherethe film to the fibrous web and particularly to adhere or bond thermoplastic fibers in the web to the film without completely compressing the fibrous web. Because of the afiinity between the material of the film and that of the thermoplastic fibers of the web when 7 they are made adhesive by the application of heat, a secure bond is formed between them, and the film and the thermoplastic fibers form an integral structure. Where the film is supported on uniformly pressed against the drum with the backing sheet between the film and the drum by the continuous belt member I that passes over the guiding and tensiomng rollers 8, 9, l0, and H. Suitable means not shown are provided for rotating the drum and the rollers in the directions shown by the arrows. The heat of the drum 6 is sufiicient to render the thermoplastic film and the thermoplastic fibers in the web tacky so that the film is bonded or adhered to the fibrous web by its own adhesiveness and that of the thermoplastic fibers in contact therewith and the film and thermoplastic fibers in contact therewith form an integral structure. The pressure of the belt is firm but is not sufiicient to completely compress the fibrous web. The fibrous web, film, and backing sheet are withdrawn from the heated drum and sent through the cooling chamber 12 which renders the film non-tacky. The backing sheet is then stripped from the thermoplastic film by the stripping roller [3 and collected on the roll IS. The film and the fibrous web are thereafter directed between the roller it that has projecting portions thereon in the form of a design and the supporting roller l5, where selected areas of the film are pressed or stamped by the projecting portions of the roller l4 and the regions of the fibrous web beneath the areas of the film that have been pressed or stamped are compressed. The supporting roller I5 is heated to a temperature sufiicient to cause the thermoplastic fibers or particles in the fibrous web to become tacky without softening the film. Directly after passing from the roller ll, the fibrousweb is cooled by an air blast or the like shown at I! which renders the adhesive fibers nonadhesive and sets the bonded fibers in the compressed regisnsor the web. The coatedweb is afterwards collected on the roll it a If desired, selected areas of the thermoplastic film may be' pressed or stamped through the backing sheet in which case the roller having theprojecting portions is positioned in advance of the cooling chamberr Figure 2 of thedrawing shows a perspective view of the product embodying the presentina other fibers 26 and prevent the compressed regions from expanding due to their natural resilience which would otherwise flatten or remove.
the depressed regions in the film that make up 2 the decorative eifect. The thermoplastic fibers bonded to the film are integral with the film. The thermoplastic fibers bonded to the other fibers and the film strengthen the fibrous web and prevent delamination.
Instead of using a film as the coating material in practicing this invention, an organisol in the form of a plaste applied to a temporary backing sheet may be used instead. The organisol may comprise a powdered or finely divided thermoplastic resin such as one of the vinyl resins in a vehicle comprising a volatile or removable liquid that does not dissolve the resin and a minor proportion of a solvent for the resin. The organisol is applied to the temporary backing sheet 4 in the form of a paste and dried so that the sheet maybe handled. When the organisol is applied to the fibrous web and subjected to heat and pressure, the resin particles flow together forming a film which is adhered as a film to the fibrous web.
vention. Reference character 20 indicates the m non-woven fibrous bonded, web and "3 the film the film and the thermop a tic fibers in the fibrous web adhesive to adhere the film to the fibrous web without substantially altering the form of the film and thermoplastic fibers, bond fibers in'the fibrous web and bond thermoplastic fiberstothefilm. p I
3. The method of making coated fibrous sheet material having'a depressed design therein that will retain the design comprising depressing selected areas of a film that is adhered to a surface of a compressible non-woven fibrous web containing thermoplastic fibers and compressing the regions of the fibrous web beneath the selected areas of the film that are depressed, rendering the thermoplastic fibers in the regions of the fibrous web beneath the areas of the film that are depressed adhesive while these regions are compressed, and rendering the adhesive fibers in the regions of the fibrous web beneath the depressed areas of the film non-adhesive while these regions are compressedto bond fibers in these regions in While preferred embodiments of this invention have been shown. hi ls to be understood that changes and variations may be made without departing from the spirit and scope of the invention as defined in the appended claims.
I claim: 1. The method of making coated fibrous sheet material comprising adhering a. film of thermoplastic material to a surface of a compressible non-woven fibrous web having thermoplastic fibers therein by pressin the film and fibrous web I together and compressing the fibrous web only a portion of the limit to which it could be compressed while subjecting the fibrous web and film o to .heat sufiicient to render the film and the therand bond thermoplastic fibers to the film.-
2. The method of making coated fibrous sheet material comprising adhering a film of thermos plastic material to a surface of a compressible non-woven fibrous web having a minor proportion of thermoplastic fibers therein by pressing the film and fibrous web together and compressing the fibrous web only a portion of the limit to which it could be compressed while subjecting the the compressed state.
4. The method of making coated fibrous sheet material having a depressed design therein that 5 will retain the design comprising depressing selected areas of a film that is adhered to a surface of a compressible non-woven fibrous web containing thermoplastic fibers and compressing the regions of the fibrous web beneath the selected areas of the film that are depressed while the thermoplastic fibers are in an adhesive state, and rendering the adhesive fibers in the region of the fibrous web beneath the depressed areas of the film non-adhesive while these regions are compressed to bond fibers in theseregions in the compressed state.
5. The method of making coated fib ous sheet material having a depressed design I rein that will retain the design comprising depressing compressible non-woven fibrous web containing a minor proportion of thermoplastic fibers and compressing the regions of the fibrous web beneath the selected areas of the film that are depressed, heating the thermoplastic fibers in the regions of the fibrous web beneath the areas of the film that are depressed to render the thermoplastic fibers adhesive while these regions are compressed, and cooling the adhesive fibers to render these fibers non-adhesive while these regions are compressed to bond fibers in these regions in the compressed state.
6. The method of making coated fibrous sheet material having a depressed design therein that will retain the design comprising depressing through the temporary backing sheet selected areas of a film on a temporary backing sheet that is adhered to a surface of a compressible non-.- woven fibrous web containing a minor proportion of thermoplastic fibers and compressing the regions of the fibrous web beneath the selected areas'of the film that are depressed, rendering the thermoplastic fibers in the regions of the fibrous webbeneath the areas of the film that are depressed adhesive while these regions are compressed, and rendering the adhesive fibers in the regions of the fibrous web beneath the depressed areas of the film non-adhesive while these regions are compressed to bond fibers in these regions in the compressed state.
7; Coated fibrous sheet material that may have a design pressed therein and the design retained comprising a thermoplastic film adhered to a surface of a compressible resilient non-woven fibrous fibrous web and film to heat suific'ient to render 15 web containing a minor proportion of thermoplastic fibers bonded to the film and other fibers, said web being relatively free or coating material throughout the body of the web and compressed to only a portion of the limit to which it can be compressed.
8. Coated fibrous sheet material that may have a design pressed therein and the design retained comprising a thermoplastic film adhered to a surface of a compressible resilient non-woven fibrous web containing thermoplastic fibers bonded-to the film and other fibers, said web being relatively free of coating material throughout the body of the web and compressed to only a portion of the limit to which it can be compressed.
0. A coated fibrous sheet material comprising a thermoplastic film having a depressed design therein adhered to a surface of a non-woven fibrous web containing a minor proportion of.
thermoplastic fibers bonded to the film and other fibers, said web being relatively free of coating material throughout the body of the web having regions beneath the depressed areas of the film comprising the design, compressed and of greater density than other portions of the web and with fibers bonded'in the regions of greater density.
10. A coated fibrous sheet material comprising a thermoplastic film having a depressed design therein adhered to a surface of a non-woven fibrous web containing thermoplastic fibers bonded to the film and other fibers, said web being relatively free of'coating material throughout the body of the web having regions beneath the depressed areas of the film comprising the design, compressed and of greater density than other portions of the web and with fibers bonded in the regions of greater density.
CARLETON S. FRANCIS. Ja.
REFERENCES CITED The following references are of record in the file of this patent:
UNITED STATES PATENTS Number Name Date 440,055 Palmer Nov. 4, 1890 1,972,923 Dreyfus et al. Sept. 11, 1934

Claims (1)

  1. 3. THE METHOD OF MAKING COATED FIBROUS SHEET MATERIAL HAVING A DEPRESSED DESIGN THEREIN THAT WILL RETAIN THE DESIGN COMPRISING DEPRESSING SELECTED AREAS OF A FILM THAT IS ADHERED TO A SURFACE OF A COMPRESSIBLE NON-WOVEN FIBROUS WEB CONTAINING THERMOPLASTIC FIBERS AND COMPRESSING THE REGIONS OF THE FIBROUS WEB BENEATH THE SELECTED AREAS OF THE FILM THAT ARE DEPRESSED, RENDERING THE THERMOPLASTIC FIBERS IN THE REGIONS OF THE FIBROUS WEB BENEATH THE AREAS OF THE FILM THAT ARE DEPRESSED ADHESIVE WHILE THESE REGIONS ARE COMPRESSED, AND RENDERING THE ADHESIVE FIBERS IN THE REGIONS OF THE FIBROUS WEB BENEATH THE DEPRESSED AREAS OF THE FILM NON-ADHESIVE WHILE THESE REGIONS ARE COMPRESSED TO BOND FIBERS IN THESE REGIONS IN THE COMPRESSED STATE.
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FR999762D FR999762A (en) 1948-08-14 1949-11-21 Process for the production of coated flbrous webs and, in particular webs having intaglio designs
BE492314D BE492314A (en) 1948-08-14 1949-11-22
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US2786790A (en) * 1953-07-03 1957-03-26 Fibre Bond Corp Laminated fabric
US2816054A (en) * 1953-04-13 1957-12-10 Permex Corp Quilted material
US2868269A (en) * 1956-02-21 1959-01-13 Gen Electric Process of treating sheet material and product resulting therefrom
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US2935668A (en) * 1951-01-05 1960-05-03 Sprague Electric Co Electrical capacitors
US2943949A (en) * 1957-10-23 1960-07-05 Congoleum Nairn Inc Decorative plastic surface covering and process therefor
US2956917A (en) * 1956-03-06 1960-10-18 Du Pont Article of manufacture and process of making same
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US3032815A (en) * 1956-08-14 1962-05-08 Braunschweiger Farbenwerke Wil Process and apparatus for manufacturing sheets from polymerizable substantially solvent-free casting resins
US3041217A (en) * 1956-10-16 1962-06-26 Celanese Corp Plastic laminates
US3046173A (en) * 1960-12-14 1962-07-24 Sackuer Products Inc Embossed plastic sheets and method of making same
US3050185A (en) * 1960-12-30 1962-08-21 Harriet R Crain Disposable place mats
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US3197355A (en) * 1961-04-20 1965-07-27 Sackner Prod Inc Method of making a pattern coated backing and product
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US3224894A (en) * 1961-06-30 1965-12-21 Congoleum Nairn Inc Process for producing decorative surface covering
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US3282771A (en) * 1962-12-17 1966-11-01 Du Pont Polyvinyl chloride film adhered to a self-bonded web of continuous oriented polypropylene filaments
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US3988519A (en) * 1975-01-13 1976-10-26 Phillips Petroleum Company Laminates of a polymeric film and a nonwoven fabric
US4503115A (en) * 1981-12-04 1985-03-05 Hoechst Aktiengesellschaft Plate-shaped molded article and process for its preparation and use
US4548856A (en) * 1983-05-16 1985-10-22 Kimberly-Clark Corporation Method for forming soft, bulky absorbent webs and resulting product
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US6277233B1 (en) * 1997-01-28 2001-08-21 Pacific Foam Technologies Customized cushioned floor mat and method of producing same
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Cited By (35)

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US2899349A (en) * 1959-08-11 Method for bonding liner materials
US2637673A (en) * 1950-01-30 1953-05-05 Reconstruction Finance Corp Nonwoven film coated fabric
US2657157A (en) * 1950-06-02 1953-10-27 American Viscose Corp Ink transfer element
US2935668A (en) * 1951-01-05 1960-05-03 Sprague Electric Co Electrical capacitors
US2816054A (en) * 1953-04-13 1957-12-10 Permex Corp Quilted material
US2786790A (en) * 1953-07-03 1957-03-26 Fibre Bond Corp Laminated fabric
US2868269A (en) * 1956-02-21 1959-01-13 Gen Electric Process of treating sheet material and product resulting therefrom
US2956917A (en) * 1956-03-06 1960-10-18 Du Pont Article of manufacture and process of making same
US3032815A (en) * 1956-08-14 1962-05-08 Braunschweiger Farbenwerke Wil Process and apparatus for manufacturing sheets from polymerizable substantially solvent-free casting resins
US3041217A (en) * 1956-10-16 1962-06-26 Celanese Corp Plastic laminates
US2943949A (en) * 1957-10-23 1960-07-05 Congoleum Nairn Inc Decorative plastic surface covering and process therefor
US3083131A (en) * 1958-09-24 1963-03-26 Specialties Dev Corp Weftless fabric and method of making the same
US2961332A (en) * 1959-07-21 1960-11-22 Congoleum Nairn Inc Process for producing decorative foam surface coverings
US3206346A (en) * 1960-11-19 1965-09-14 Nuorivaara Ensio Method of treatment of porous wallboard
US3167464A (en) * 1960-12-12 1965-01-26 Cougoleum Nairn Inc Decorative surface covering and process for preparing same
US3046173A (en) * 1960-12-14 1962-07-24 Sackuer Products Inc Embossed plastic sheets and method of making same
US3050185A (en) * 1960-12-30 1962-08-21 Harriet R Crain Disposable place mats
US3180782A (en) * 1961-03-09 1965-04-27 Celanese Corp Textile material and method for making same
US3197355A (en) * 1961-04-20 1965-07-27 Sackner Prod Inc Method of making a pattern coated backing and product
US3230123A (en) * 1961-06-23 1966-01-18 Lockheed Aircraft Corp Method and apparatus for forming a tube of spirally wound tapes
US3224894A (en) * 1961-06-30 1965-12-21 Congoleum Nairn Inc Process for producing decorative surface covering
US3245862A (en) * 1962-08-15 1966-04-12 Olij Hermanus Cornelis Processes and apparatuses for coating under temporary heating and pressure of foil material with thermoplastic plastic foil
US3282771A (en) * 1962-12-17 1966-11-01 Du Pont Polyvinyl chloride film adhered to a self-bonded web of continuous oriented polypropylene filaments
US3285800A (en) * 1963-02-25 1966-11-15 Armstrong Cork Co Cushioning and wrapping laminate
US3301741A (en) * 1963-09-11 1967-01-31 Minnesota Mining & Mfg Adhesive sheet and method of making
US3940528A (en) * 1965-05-14 1976-02-24 Roberts Arthur H Rigid plastics tile with textured surface
US3520760A (en) * 1968-04-19 1970-07-14 Kaumagraph Co Transfer sheet having shaped thermoplastic transfer for stiffening or reinforcing fabric apparel and shoes
US3933558A (en) * 1972-05-29 1976-01-20 Kohjin Co., Ltd. Method of processing laminated decorative sheet for imparting permanent shape thereto
US3988519A (en) * 1975-01-13 1976-10-26 Phillips Petroleum Company Laminates of a polymeric film and a nonwoven fabric
US4503115A (en) * 1981-12-04 1985-03-05 Hoechst Aktiengesellschaft Plate-shaped molded article and process for its preparation and use
US4548856A (en) * 1983-05-16 1985-10-22 Kimberly-Clark Corporation Method for forming soft, bulky absorbent webs and resulting product
EP0344365A2 (en) * 1988-05-28 1989-12-06 Johann Borgers GmbH. & Co. KG Padded member for seating and lying furniture or the like
EP0344365A3 (en) * 1988-05-28 1990-12-19 Johann Borgers Gmbh. & Co. Kg Padded member for seating and lying furniture or the like
US6277233B1 (en) * 1997-01-28 2001-08-21 Pacific Foam Technologies Customized cushioned floor mat and method of producing same
US20110281076A1 (en) * 2009-01-09 2011-11-17 Johnson Controls Technology Company Natural Fiber Trim Panel

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Publication number Publication date
GB673129A (en) 1952-06-04
BE492314A (en) 1949-12-15
FR999762A (en) 1952-02-05

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