CA2297699A1 - Double-sided polymer laminar sheet and use - Google Patents
Double-sided polymer laminar sheet and use Download PDFInfo
- Publication number
- CA2297699A1 CA2297699A1 CA 2297699 CA2297699A CA2297699A1 CA 2297699 A1 CA2297699 A1 CA 2297699A1 CA 2297699 CA2297699 CA 2297699 CA 2297699 A CA2297699 A CA 2297699A CA 2297699 A1 CA2297699 A1 CA 2297699A1
- Authority
- CA
- Canada
- Prior art keywords
- layer
- scrim
- polymer
- sheet
- curtain
- 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.)
- Abandoned
Links
Landscapes
- Laminated Bodies (AREA)
Abstract
A laminar sheet made by bonding a layer of polymer, such as vinyl or polyester to each side of a layer of scrim to produce a laminar sheet and method to produce the sheet.
Description
Attorney Docket No. 12204/06701 99-PB-42 DOUBLE-SIDED-POLYI~R LAMINAR SHEET AND USE
TECHNICAL FIELD OF THE INVENTION
This invention relates to a pliable double-sided -~~lymer laminar sheet . In one aspen, i~ relates tv a laminar material having a scrim layer sandwiched between two layers of pliable polymer having various uses. In another aspect, it relates to a method of making a pliable double-sided polymer laminar sheet.
s Attorney Docket No. 12204/6701 99-PB-42 EACKGROUND OF THE INVENTION
Pliable polymer material is often used on upholstered objects, articles of apparel, household objects, and vehicle interiors instead of leather or to simulate leather. These materials are typically made by a polymer such as vinyl or polyurethane. It is known to use a single layer of pliable polymer for such uses.
It is also known to use a laminar sheet of polymer vinyl such as polyurethane or for such uses. The known pliable laminar sheet of polymer typically consists of a scrim layer integrally bonded with a pliable polymer layer. The scrim layer can be woven, nonwoven or knitted. The scrim is used to provide some dimensional stability and increased strength for the polymer laminar sheet. The prior polymer laminar sheets with a scrim layer have one surface with the scrim layer exposed and the opposite surface with the pliable polymer layer exposed. The exposed polymer surface may be textured to resemble other materials, such as leather. In addition, the polymer layer may be created in a wide variety of colors.
In most of the uses of a pliable polymer laminar sheet, only one side of the material will be seen. For example, using a pliable polymer laminar sheet for a seat cover only requires that one side be seen when installed on the seat. But there are other applications where both sides of a material will be Attorney Docket No. 12204/6701 99-PB-42 seen. For example, a privacy curtain is typically used in a truck operator compartment to separate a truck sleeper from the truck cab. In such use, both sides of the curtain will be seen during use. In the past, such curtains made using a pliable polymer laminar material required that two sheets be sewn together, back-to-back (i.e., scrim side-to-scrim side), to provide the desired appearance of having textured polymer on each side. However by sewing two sheets together, special equipment is required. The weight is doubled and the pliability of the curtain is reduced. It is often desirable to decrease the weight of a vehicle, aircraft, or boat to enhance handling characteristics, improve fuel economy, decrease inertia for braking, and increase the power-to-weight ratio for acceleration or pulling power. Also, there is often more cost associated with manufacturing a object requiring two sheets to be sewn together as compared to the cost of an object having only a single sheet of material.
Therefore, a need exists for a way to decrease the manufacturing cost and decrease the weight for an application requiring both sides of a sheet to be viewed, while not diminishing the appearance and functionality of the application.
The dimensional stability was highly affected by the scrim utilized. The importance of dimensional stability is a function of several factors, such as loads to be expected, direction of loads, and expected life cycle. Scrims of knitted and non woven fabric Attorney Docket No. 12204/6701 99-PB-42 used to make polymer sheets were undesirable or less desirable in certain applications, but were used because of cost considerations. Thus, there is a need for an improved polymer sheet which has improved strength and dimensional stability as well as being cost effective.
TECHNICAL FIELD OF THE INVENTION
This invention relates to a pliable double-sided -~~lymer laminar sheet . In one aspen, i~ relates tv a laminar material having a scrim layer sandwiched between two layers of pliable polymer having various uses. In another aspect, it relates to a method of making a pliable double-sided polymer laminar sheet.
s Attorney Docket No. 12204/6701 99-PB-42 EACKGROUND OF THE INVENTION
Pliable polymer material is often used on upholstered objects, articles of apparel, household objects, and vehicle interiors instead of leather or to simulate leather. These materials are typically made by a polymer such as vinyl or polyurethane. It is known to use a single layer of pliable polymer for such uses.
It is also known to use a laminar sheet of polymer vinyl such as polyurethane or for such uses. The known pliable laminar sheet of polymer typically consists of a scrim layer integrally bonded with a pliable polymer layer. The scrim layer can be woven, nonwoven or knitted. The scrim is used to provide some dimensional stability and increased strength for the polymer laminar sheet. The prior polymer laminar sheets with a scrim layer have one surface with the scrim layer exposed and the opposite surface with the pliable polymer layer exposed. The exposed polymer surface may be textured to resemble other materials, such as leather. In addition, the polymer layer may be created in a wide variety of colors.
In most of the uses of a pliable polymer laminar sheet, only one side of the material will be seen. For example, using a pliable polymer laminar sheet for a seat cover only requires that one side be seen when installed on the seat. But there are other applications where both sides of a material will be Attorney Docket No. 12204/6701 99-PB-42 seen. For example, a privacy curtain is typically used in a truck operator compartment to separate a truck sleeper from the truck cab. In such use, both sides of the curtain will be seen during use. In the past, such curtains made using a pliable polymer laminar material required that two sheets be sewn together, back-to-back (i.e., scrim side-to-scrim side), to provide the desired appearance of having textured polymer on each side. However by sewing two sheets together, special equipment is required. The weight is doubled and the pliability of the curtain is reduced. It is often desirable to decrease the weight of a vehicle, aircraft, or boat to enhance handling characteristics, improve fuel economy, decrease inertia for braking, and increase the power-to-weight ratio for acceleration or pulling power. Also, there is often more cost associated with manufacturing a object requiring two sheets to be sewn together as compared to the cost of an object having only a single sheet of material.
Therefore, a need exists for a way to decrease the manufacturing cost and decrease the weight for an application requiring both sides of a sheet to be viewed, while not diminishing the appearance and functionality of the application.
The dimensional stability was highly affected by the scrim utilized. The importance of dimensional stability is a function of several factors, such as loads to be expected, direction of loads, and expected life cycle. Scrims of knitted and non woven fabric Attorney Docket No. 12204/6701 99-PB-42 used to make polymer sheets were undesirable or less desirable in certain applications, but were used because of cost considerations. Thus, there is a need for an improved polymer sheet which has improved strength and dimensional stability as well as being cost effective.
Attorney Docket No. 12204/06701 99-PB-42 SUI~1ARY OF THE INVENTION
In accordance with one aspect of the present invention, a laminar double sided polymer sheet is provided. The sheet is made by applying a polymer to each side of a scrim layer. Thus, the invention provides in one embodiment a sheet made from a layer of scrim having first and second sides. A first layer of polymer is applied to the first side of the scrim and a second polymer layer is applied to the second side of the scrim. The exposed surfaces of the polymer may be textured to resemble leather.
In a preferred embodiment the scrim is a knitted fabric and the polymer layers are vinyl.
The method is to provide a layer of scrim, to apply a first layer of polymer to one side of the scrim; and to apply a second layer of polymer to the second side of the scrim. In a preferred embodiment the outer surfaces of the polymer layers are embossed to resemble leather.
In accordance with one aspect of the present invention, a laminar double sided polymer sheet is provided. The sheet is made by applying a polymer to each side of a scrim layer. Thus, the invention provides in one embodiment a sheet made from a layer of scrim having first and second sides. A first layer of polymer is applied to the first side of the scrim and a second polymer layer is applied to the second side of the scrim. The exposed surfaces of the polymer may be textured to resemble leather.
In a preferred embodiment the scrim is a knitted fabric and the polymer layers are vinyl.
The method is to provide a layer of scrim, to apply a first layer of polymer to one side of the scrim; and to apply a second layer of polymer to the second side of the scrim. In a preferred embodiment the outer surfaces of the polymer layers are embossed to resemble leather.
Attorney Docket No. 12204/06701 99-PB-42 BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and advantages of the present invention will become apparent upon reading the following detailed description and upon reference to the accompanying drawings in which:
FIG. lA is a perspective view of a laminar sheet of the prior art;
FIG. 1B is an end view of the laminar sheet shown in FIG. la;
FIG. 2A is a perspective view of a first embodiment of the present invention;
FIG. 2B is an end view of the embodiment shown in FIG. 2a;
FIG. 2C is an end view of the embodiment shown in FIGS. 2A and 2B having a side split open for illustration purposes;
FIG. 3A is a partial cross sectional view of a prior art privacy curtain;
FIGS. 3B and 3C are partial cross sectional views of privacy curtains of the present invention.
FIG. 4 is a side view of an embodiment illustrating a method of the present invention.
FIG. 5 is a side view of another embodiment illustrating a method of the present invention; and Attorney Docket No. 12204/6701 99-PB-42 FIG. 6 is a perspective view of a truck having a portion broken away to illustrate other embodiments of the present invention incorporated therein.
_ 7 _ Attorney Docket No. 12204/06701 99-PB-42 DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings, wherein like reference numbers are used to designate like elements throughout the various views, several embodiments of the present invention are further described. FIGS. lA
and 1B show a laminar sheet 20 consisting of a scrim layer 22 on one side and a polymer layer 24 on the opposite side, which is the prior art.
FIG. 2A is perspective view of a first embodiment of the present invention. FIG. 2B is an end view of the first embodiment shown in FIG. 2A. FIG. 2C is an end view of the first embodiment shown in FIGS. 2A and 2B, but with one side split open for illustration purposes. Referring to FIGS. 2A and 2B, a pliable single laminar sheet 30 is formed by a scrim layer 32 sandwiched between a first pliable polymer layer 34 and a second pliable polymer layer 36. The laminar sheet 30 has a first exposed surface 38 and a second exposed surface 40. The scrim layer can be a woven, knit or nonwoven fabric. The scrim fabric can be of nylon, polyester, acrylic, cotton, rayon, nylon or other suitable material. The polymer can be of vinyl or polyurethane. In the preferred embodiment the polymer is vinyl. The invention will be discussed in reference to the preferred embodiment of utilizing vinyl.
As shown in FIG. 2C, the first polymer layer 34 has an inner side 42 and an outer side 44. The inner side 42 of the first polymer layer 34 is bonded upon a _ g _ t Attorney Docket No. 12204/6701 99-PB-42 first side 46 of the scrim layer 32. The outer side 44 of the first polymer layer 34 forms the first exposed surface 38 of the laminar sheet 30. Similarly, the second polymer layer 36 has an inner side 48 and an outer side 50. The inner side 48 of the second polymer layer 36 is bonded upon a second side 52 of the scrim layer 32. The first scrim side 46 is opposite of the second scrim side 52. The outer side 50 of the second polymer layer 36 forms the second exposed surface 40 of the laminar sheet 30. The exposed surfaces 38 and 40 can be a textured surface so that the laminar sheet 30 resembles leather on both sides. Other types of textured surfaces may be used as well.
In the preferred embodiment the scrim is a knitted fabric because it gives good performance at reasonable cost. In the preferred embodiment the total thickness of the pliable sheet 30 is from 30 to 50 thousands (0.03 - 0.05 inch) of an inch in thickness; and the thickness of each of the first and second layers (34, 36) is from 4 to 10 thousands of an inch. It will be understood that the polymer will likely penetrate into the scrim; thus, thickness of the polymer layer relates to the thickness of the layer above the scrim. The vinyl layers can be thicker if desired. Also, the overall thickness can be greater. For applications as a privacy curtain, a total thickness of about 40 thousands of an inch is acceptable. Also, in the preferred embodiment the weight of the pliable sheet 30 is from 500 to 600 grams per square meter (14.7 to 17.7 _ g _ Attorney Docket No. 12204/6701 99-PB-42 ounces per square yard). Other characteristics of the preferred embodiment include:
(a) a tensile strength of 70 to 90 pounds in the wrap direction and 50 to 60 pounds in the fill (weave) direction by ASTM D751-79; and (b) a tear strength of 15 to 21 pounds in the wrap direction and 14 to 18 in the fill direction by ASTM D751-79.
The present invention allows for a weight savings of about 15 pounds over curtains made by the prior art for use in large trucks.
It was surprisingly found that the dimensional stability was greatly increased by the application of a vinyl layer to each side of scrim when to total thickness was the same. A prior art sheet having a total thickness of 0.040 inches with vinyl layer applied to one side of a knitted scrim had poor dimensional stability in the weave or fill direction.
Under tension in the weave direction the curtain would deform. However, when the knitted scrim had a vinyl layer applied to both sides in accordance with the present invention, the dimensional stability was greatly increased in the weave direction, even though the resulting sheet was the same thickness. It is expected that the directional stability of nonwoven and woven fabric would be improved also. In a test a 6 inch by 3 inch sample of the prior art and present Attorney Docket No. 12204/6701 99-PB-42 invention were tested. The 6 inch dimension was in the weave direction and the 3 inch dimension was in the wrap direction. In the prior art sample the vinyl coating was on one side of the knitted scrim and the sample had a thickness of 0.04 inches. The sample of the present invention had a layer of vinyl on each side of the knitted scrim and the sample was 0.04 inches thick. Both samples were stretched manually by pulling on them. The prior art sample could be stretched about 1.25 inches in the weave direction and 0.25 inches in the wrap direction. The sample of the present invention could be stretched about 0.25 inches in the weave direction and no stretch was observed in the wrap direction.
Another feature of the present invention is that an edge is produced which does not have to be hemmed in order to be aesthetically pleasing.
FIG. lb illustrates the edge of the prior art sheet 20. Visual inspection of the edge shows that there are two distinct portions, the vinyl layer 24, and the scrim 22. In contrast, when viewing an edge view of a sheet made according to the present invention it is very difficult to detect the scrim layer. Thus, the present invention when cut appears much the same as leather, that is, the consistency of the edge appears uniform. Thus, the present invention does not require a hem.
Attorney Docket No. 12204/6701 99-PB-42 The elimination or the reduction in the hem is an advantage. If no hem is used, labor is saved. If the sheet of the present invention is hemmed for a two sided curtain the hem is reduced in thickness and thus easier to sew.
FIG. 3A illustrates a cross sectional view of the normal construction of a prior art truck privacy curtain 19.
Two sheets 20 are placed with the scrim layers 22 facing each other. The ends 21 of each sheet are folded over and the sheets sewn together with thread 25. Obtaining and maintaining proper alignment during sewing is difficult. Also, the combined thickness is that of four sheets 20.
In contrast, as shown in Figures 3B and 3C, the present invention allows for a hem having only two or three thicknesses and which does not require alignment of two separate sheets. FIG. 3B shows a cross section of a sheet 30 having scrim layer 32 with a first and second vinyl layer 34, 36 applied thereto. The end 29 of sheet 30 folded over and sewn down by thread 31. In FIG. 3C the hem is made by folding end 33 and then folding sheet 30 again so that edge 35 is no longer exposed. The hem is sewn together by thread 37.
FIG. 4 illustrates the method of producing the sheet of the present invention utilizing vinyl as the polymer layers. The vinyl can be to the scrim by any Attorney Docket No. 12204/6701 99-PB-42 known method such as extrusion, calandering and paste coating. Referring to Figure 4, in the method scrim 32 is delivered from a delivery roll 80. The first side 46 of the scrim 32 passes under applicator 82 which applies vinyl to form first layer 34. The embossing rollers 84 emboss the desired pattern on the vinyl.
The scrim 34 then passes second applicator which applies the second layer 36 to the second side 52 of the scrim 32. The second layer 36 is embossed if desired by embossing rollers 88, and finish products stored on take up roll 90.
FIG. 5 is a side view of another embodiment of the present invention utilizing a casting technique and a polyester polymer. In this method of producing a single laminar sheet 30, a scrim layer 32 integrally sandwiched between a first pliable polyester layer 34 and a second pliable polyester layer 36. The method illustrated in FIG. 5 has a first stage (indicated by reference number 54) of applicating the first polyester layer 34 on the scrim layer 32. At this first stage 54, the inner side 42 of the first polyester layer 34 is integrally attached to a first side 46 of the scrim layer 32. Also, as the first polyester layer 34 is being deposited upon the scrim layer 32 at the first stage 54, a leather textured surface is formed on the outer side 44 of the first polyester layer 34. After the first stage 54, an intermediate laminar sheet 56 is then feed to a second stage (indicated by reference number 58). At the second stage 58, the second Attorney Docket No. 12204/6701 99-PB-42 polyester layer 36 is deposited on the intermediate laminar sheet 56 to create the laminar sheet 30 having the scrim layer 32 integrally sandwiched between the first polyester layer 34 and the second polyester layer 36. More specifically, at the second stage 58 the inner side 48 of the second polyester layer 36 is integrally attached to a second side 52 of the scrim layer 32. The second side 52 and the first side 46 of the scrim layer 32 are opposite each other. Also, as the second polyester layer 36 is being deposited upon the scrim layer 32 at the second stage 58, another leather textured surface is formed on the outer side 50 of the second polyester layer 36. Hence, the finished product of the laminar sheet 30 has a leather textured surface on both sides 38, 40. However, other types of textured surfaces may be formed on either side as well.
FIG. 6 shows a truck 60 incorporating additional embodiments of the present invention. A portion of the truck 60 in FIG. 6 has been broken away to better illustrate the interior of the truck operator compartment 62. A privacy curtain 64 separates the truck cab 66 from the truck sleeper 68. The privacy curtain 64 may be made from a single layer of laminar sheet having a scrim layer sandwiched between a first pliable polymer layer and a second pliable polymer layer, as described in the first embodiment above herein and shown in FIGS. 2A-2C. The exposed surfaces 38, 40 may have a leather textured surface so that the curtain 64 resembles leather on both sides. But other Attorney Docket No. 12204/6701 99-PB-42 types of textured surfaces may be formed on either side as well.
The privacy curtain 64 may be attached to the truck operator compartment 62 by various means. Loops may attach the curtain 64 to a curtain rod, which will allow portions of, or all of, the curtain to be slide laterally to provide access between the truck cab 66 and the truck sleeper 68. In alternative, the curtains 64 may have a series rigid members displace laterally along the top of the curtain. A slide track may be attached to the truck operator compartment 62 proximate to the top of the curtain 64 and laterally across the truck operator compartment. The rigid members fit within the slide track such that the curtain 64 is attached to the slide track and portions of, or all of, the curtain may slide laterally along the slide track.
Hence, the privacy curtain 64 may be opened, partially closed, or completely closed to provide various levels of privacy within the truck cab 66 or within the truck sleeper 68.
The present invention also encompasses other types of curtains for trucks made using a laminar sheet of the type having a scrim layer sandwiched between a first pliable polymer layer and a second pliable polymer layer as previously described. Referring still to FIG. 6, upper and lower sleeper window curtains 91 and 92, respectively, are shown positioned behind upper and lower sleeper windows 93 and 94, respectively, to Attorney Docket No. 12204/6701 99-PB-42 provide increased light control and privacy for the sleeper compartment 68. Each sleeper window curtain 91, 92 may be formed from a single sheet of the polymer/scrim/polymer sandwich laminar sheet having dimensions selected to cover the window. Such curtain 91, 92 can be held in place using snap fittings 95 positioned along the periphery of the curtain corresponding to snap fittings (not shown) on the interior hard trim surrounding the window. Other attachment methods, such as hook-and-loop material, could also be used to secure the window curtains over the windows. In yet another embodiment, a cab privacy curtain 96 may be made using the polymer/scrim/polymer material for attachment along the inside of the windshield 97 and cab side windows to provide increased light control and privacy for the cab. Prior art window curtains made using materials having a polymer layer on one exposed surface and a backing scrim on the other exposed surface had the disadvantage that the unattractive backing scrim would be visible.through the window of the vehicle, or alternatively (to present a finished appearance inside and out), the curtain had to be constructed using two layers of single-layer material with the scrim sides facing each other, resulting in higher weight for the curtain.
FIG. 6 also shows a further embodiment of the present invention. The seats within the truck operator compartment 62 have reversible seat covers 70 thereon.
The reversible seat covers 70 may provide a way to have Attorney Docket No. 12204/6701 99-PB-42 a first color or surface texture on one side and a second (possibly different) color or surface texture on the other side. Such reversible seat covers 70 may be made from a single laminar sheet material 30 having a single scrim layer 32 integrally imbedded between a first pliable polymer layer 34 and a second pliable polymer layer 36, as described in the first embodiment discussed above herein and shown in FIGS. 2A-2C. The reversible seat covers 70 may have a leather textured surface on both sides such that the material resembles leather on both sides. But other types of textured surfaces may be formed on either side as well. The seat covers 70 may incorporate an elastic band around the edges to maintain position of a seat cover on a seat.
It will be appreciated by those skilled in the art having the benefit of this disclosure that this invention provides a pliable double-sided polymer laminar sheet of material, use thereof, and method of making such material. It should be understood that the drawings and detailed description herein are to be regarded in an illustrative rather than a restrictive sense, and are not intended to limit the invention to the particular forms disclosed. On the contrary, the invention includes any further modifications, changes, rearrangements, substitutions, alternatives, design choices, and embodiments apparent to those of ordinary skill in the art without departing from the spirit and scope of this invention, as defined by the following Attorney Docket No. 12204/6701 99-PB-42 claims. Thus, it is intended that the following claims be interpreted to embrace all such further modifications, changes, rearrangements, substitutions, alternatives, design choices, and embodiments.
Other objects and advantages of the present invention will become apparent upon reading the following detailed description and upon reference to the accompanying drawings in which:
FIG. lA is a perspective view of a laminar sheet of the prior art;
FIG. 1B is an end view of the laminar sheet shown in FIG. la;
FIG. 2A is a perspective view of a first embodiment of the present invention;
FIG. 2B is an end view of the embodiment shown in FIG. 2a;
FIG. 2C is an end view of the embodiment shown in FIGS. 2A and 2B having a side split open for illustration purposes;
FIG. 3A is a partial cross sectional view of a prior art privacy curtain;
FIGS. 3B and 3C are partial cross sectional views of privacy curtains of the present invention.
FIG. 4 is a side view of an embodiment illustrating a method of the present invention.
FIG. 5 is a side view of another embodiment illustrating a method of the present invention; and Attorney Docket No. 12204/6701 99-PB-42 FIG. 6 is a perspective view of a truck having a portion broken away to illustrate other embodiments of the present invention incorporated therein.
_ 7 _ Attorney Docket No. 12204/06701 99-PB-42 DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings, wherein like reference numbers are used to designate like elements throughout the various views, several embodiments of the present invention are further described. FIGS. lA
and 1B show a laminar sheet 20 consisting of a scrim layer 22 on one side and a polymer layer 24 on the opposite side, which is the prior art.
FIG. 2A is perspective view of a first embodiment of the present invention. FIG. 2B is an end view of the first embodiment shown in FIG. 2A. FIG. 2C is an end view of the first embodiment shown in FIGS. 2A and 2B, but with one side split open for illustration purposes. Referring to FIGS. 2A and 2B, a pliable single laminar sheet 30 is formed by a scrim layer 32 sandwiched between a first pliable polymer layer 34 and a second pliable polymer layer 36. The laminar sheet 30 has a first exposed surface 38 and a second exposed surface 40. The scrim layer can be a woven, knit or nonwoven fabric. The scrim fabric can be of nylon, polyester, acrylic, cotton, rayon, nylon or other suitable material. The polymer can be of vinyl or polyurethane. In the preferred embodiment the polymer is vinyl. The invention will be discussed in reference to the preferred embodiment of utilizing vinyl.
As shown in FIG. 2C, the first polymer layer 34 has an inner side 42 and an outer side 44. The inner side 42 of the first polymer layer 34 is bonded upon a _ g _ t Attorney Docket No. 12204/6701 99-PB-42 first side 46 of the scrim layer 32. The outer side 44 of the first polymer layer 34 forms the first exposed surface 38 of the laminar sheet 30. Similarly, the second polymer layer 36 has an inner side 48 and an outer side 50. The inner side 48 of the second polymer layer 36 is bonded upon a second side 52 of the scrim layer 32. The first scrim side 46 is opposite of the second scrim side 52. The outer side 50 of the second polymer layer 36 forms the second exposed surface 40 of the laminar sheet 30. The exposed surfaces 38 and 40 can be a textured surface so that the laminar sheet 30 resembles leather on both sides. Other types of textured surfaces may be used as well.
In the preferred embodiment the scrim is a knitted fabric because it gives good performance at reasonable cost. In the preferred embodiment the total thickness of the pliable sheet 30 is from 30 to 50 thousands (0.03 - 0.05 inch) of an inch in thickness; and the thickness of each of the first and second layers (34, 36) is from 4 to 10 thousands of an inch. It will be understood that the polymer will likely penetrate into the scrim; thus, thickness of the polymer layer relates to the thickness of the layer above the scrim. The vinyl layers can be thicker if desired. Also, the overall thickness can be greater. For applications as a privacy curtain, a total thickness of about 40 thousands of an inch is acceptable. Also, in the preferred embodiment the weight of the pliable sheet 30 is from 500 to 600 grams per square meter (14.7 to 17.7 _ g _ Attorney Docket No. 12204/6701 99-PB-42 ounces per square yard). Other characteristics of the preferred embodiment include:
(a) a tensile strength of 70 to 90 pounds in the wrap direction and 50 to 60 pounds in the fill (weave) direction by ASTM D751-79; and (b) a tear strength of 15 to 21 pounds in the wrap direction and 14 to 18 in the fill direction by ASTM D751-79.
The present invention allows for a weight savings of about 15 pounds over curtains made by the prior art for use in large trucks.
It was surprisingly found that the dimensional stability was greatly increased by the application of a vinyl layer to each side of scrim when to total thickness was the same. A prior art sheet having a total thickness of 0.040 inches with vinyl layer applied to one side of a knitted scrim had poor dimensional stability in the weave or fill direction.
Under tension in the weave direction the curtain would deform. However, when the knitted scrim had a vinyl layer applied to both sides in accordance with the present invention, the dimensional stability was greatly increased in the weave direction, even though the resulting sheet was the same thickness. It is expected that the directional stability of nonwoven and woven fabric would be improved also. In a test a 6 inch by 3 inch sample of the prior art and present Attorney Docket No. 12204/6701 99-PB-42 invention were tested. The 6 inch dimension was in the weave direction and the 3 inch dimension was in the wrap direction. In the prior art sample the vinyl coating was on one side of the knitted scrim and the sample had a thickness of 0.04 inches. The sample of the present invention had a layer of vinyl on each side of the knitted scrim and the sample was 0.04 inches thick. Both samples were stretched manually by pulling on them. The prior art sample could be stretched about 1.25 inches in the weave direction and 0.25 inches in the wrap direction. The sample of the present invention could be stretched about 0.25 inches in the weave direction and no stretch was observed in the wrap direction.
Another feature of the present invention is that an edge is produced which does not have to be hemmed in order to be aesthetically pleasing.
FIG. lb illustrates the edge of the prior art sheet 20. Visual inspection of the edge shows that there are two distinct portions, the vinyl layer 24, and the scrim 22. In contrast, when viewing an edge view of a sheet made according to the present invention it is very difficult to detect the scrim layer. Thus, the present invention when cut appears much the same as leather, that is, the consistency of the edge appears uniform. Thus, the present invention does not require a hem.
Attorney Docket No. 12204/6701 99-PB-42 The elimination or the reduction in the hem is an advantage. If no hem is used, labor is saved. If the sheet of the present invention is hemmed for a two sided curtain the hem is reduced in thickness and thus easier to sew.
FIG. 3A illustrates a cross sectional view of the normal construction of a prior art truck privacy curtain 19.
Two sheets 20 are placed with the scrim layers 22 facing each other. The ends 21 of each sheet are folded over and the sheets sewn together with thread 25. Obtaining and maintaining proper alignment during sewing is difficult. Also, the combined thickness is that of four sheets 20.
In contrast, as shown in Figures 3B and 3C, the present invention allows for a hem having only two or three thicknesses and which does not require alignment of two separate sheets. FIG. 3B shows a cross section of a sheet 30 having scrim layer 32 with a first and second vinyl layer 34, 36 applied thereto. The end 29 of sheet 30 folded over and sewn down by thread 31. In FIG. 3C the hem is made by folding end 33 and then folding sheet 30 again so that edge 35 is no longer exposed. The hem is sewn together by thread 37.
FIG. 4 illustrates the method of producing the sheet of the present invention utilizing vinyl as the polymer layers. The vinyl can be to the scrim by any Attorney Docket No. 12204/6701 99-PB-42 known method such as extrusion, calandering and paste coating. Referring to Figure 4, in the method scrim 32 is delivered from a delivery roll 80. The first side 46 of the scrim 32 passes under applicator 82 which applies vinyl to form first layer 34. The embossing rollers 84 emboss the desired pattern on the vinyl.
The scrim 34 then passes second applicator which applies the second layer 36 to the second side 52 of the scrim 32. The second layer 36 is embossed if desired by embossing rollers 88, and finish products stored on take up roll 90.
FIG. 5 is a side view of another embodiment of the present invention utilizing a casting technique and a polyester polymer. In this method of producing a single laminar sheet 30, a scrim layer 32 integrally sandwiched between a first pliable polyester layer 34 and a second pliable polyester layer 36. The method illustrated in FIG. 5 has a first stage (indicated by reference number 54) of applicating the first polyester layer 34 on the scrim layer 32. At this first stage 54, the inner side 42 of the first polyester layer 34 is integrally attached to a first side 46 of the scrim layer 32. Also, as the first polyester layer 34 is being deposited upon the scrim layer 32 at the first stage 54, a leather textured surface is formed on the outer side 44 of the first polyester layer 34. After the first stage 54, an intermediate laminar sheet 56 is then feed to a second stage (indicated by reference number 58). At the second stage 58, the second Attorney Docket No. 12204/6701 99-PB-42 polyester layer 36 is deposited on the intermediate laminar sheet 56 to create the laminar sheet 30 having the scrim layer 32 integrally sandwiched between the first polyester layer 34 and the second polyester layer 36. More specifically, at the second stage 58 the inner side 48 of the second polyester layer 36 is integrally attached to a second side 52 of the scrim layer 32. The second side 52 and the first side 46 of the scrim layer 32 are opposite each other. Also, as the second polyester layer 36 is being deposited upon the scrim layer 32 at the second stage 58, another leather textured surface is formed on the outer side 50 of the second polyester layer 36. Hence, the finished product of the laminar sheet 30 has a leather textured surface on both sides 38, 40. However, other types of textured surfaces may be formed on either side as well.
FIG. 6 shows a truck 60 incorporating additional embodiments of the present invention. A portion of the truck 60 in FIG. 6 has been broken away to better illustrate the interior of the truck operator compartment 62. A privacy curtain 64 separates the truck cab 66 from the truck sleeper 68. The privacy curtain 64 may be made from a single layer of laminar sheet having a scrim layer sandwiched between a first pliable polymer layer and a second pliable polymer layer, as described in the first embodiment above herein and shown in FIGS. 2A-2C. The exposed surfaces 38, 40 may have a leather textured surface so that the curtain 64 resembles leather on both sides. But other Attorney Docket No. 12204/6701 99-PB-42 types of textured surfaces may be formed on either side as well.
The privacy curtain 64 may be attached to the truck operator compartment 62 by various means. Loops may attach the curtain 64 to a curtain rod, which will allow portions of, or all of, the curtain to be slide laterally to provide access between the truck cab 66 and the truck sleeper 68. In alternative, the curtains 64 may have a series rigid members displace laterally along the top of the curtain. A slide track may be attached to the truck operator compartment 62 proximate to the top of the curtain 64 and laterally across the truck operator compartment. The rigid members fit within the slide track such that the curtain 64 is attached to the slide track and portions of, or all of, the curtain may slide laterally along the slide track.
Hence, the privacy curtain 64 may be opened, partially closed, or completely closed to provide various levels of privacy within the truck cab 66 or within the truck sleeper 68.
The present invention also encompasses other types of curtains for trucks made using a laminar sheet of the type having a scrim layer sandwiched between a first pliable polymer layer and a second pliable polymer layer as previously described. Referring still to FIG. 6, upper and lower sleeper window curtains 91 and 92, respectively, are shown positioned behind upper and lower sleeper windows 93 and 94, respectively, to Attorney Docket No. 12204/6701 99-PB-42 provide increased light control and privacy for the sleeper compartment 68. Each sleeper window curtain 91, 92 may be formed from a single sheet of the polymer/scrim/polymer sandwich laminar sheet having dimensions selected to cover the window. Such curtain 91, 92 can be held in place using snap fittings 95 positioned along the periphery of the curtain corresponding to snap fittings (not shown) on the interior hard trim surrounding the window. Other attachment methods, such as hook-and-loop material, could also be used to secure the window curtains over the windows. In yet another embodiment, a cab privacy curtain 96 may be made using the polymer/scrim/polymer material for attachment along the inside of the windshield 97 and cab side windows to provide increased light control and privacy for the cab. Prior art window curtains made using materials having a polymer layer on one exposed surface and a backing scrim on the other exposed surface had the disadvantage that the unattractive backing scrim would be visible.through the window of the vehicle, or alternatively (to present a finished appearance inside and out), the curtain had to be constructed using two layers of single-layer material with the scrim sides facing each other, resulting in higher weight for the curtain.
FIG. 6 also shows a further embodiment of the present invention. The seats within the truck operator compartment 62 have reversible seat covers 70 thereon.
The reversible seat covers 70 may provide a way to have Attorney Docket No. 12204/6701 99-PB-42 a first color or surface texture on one side and a second (possibly different) color or surface texture on the other side. Such reversible seat covers 70 may be made from a single laminar sheet material 30 having a single scrim layer 32 integrally imbedded between a first pliable polymer layer 34 and a second pliable polymer layer 36, as described in the first embodiment discussed above herein and shown in FIGS. 2A-2C. The reversible seat covers 70 may have a leather textured surface on both sides such that the material resembles leather on both sides. But other types of textured surfaces may be formed on either side as well. The seat covers 70 may incorporate an elastic band around the edges to maintain position of a seat cover on a seat.
It will be appreciated by those skilled in the art having the benefit of this disclosure that this invention provides a pliable double-sided polymer laminar sheet of material, use thereof, and method of making such material. It should be understood that the drawings and detailed description herein are to be regarded in an illustrative rather than a restrictive sense, and are not intended to limit the invention to the particular forms disclosed. On the contrary, the invention includes any further modifications, changes, rearrangements, substitutions, alternatives, design choices, and embodiments apparent to those of ordinary skill in the art without departing from the spirit and scope of this invention, as defined by the following Attorney Docket No. 12204/6701 99-PB-42 claims. Thus, it is intended that the following claims be interpreted to embrace all such further modifications, changes, rearrangements, substitutions, alternatives, design choices, and embodiments.
Claims (20)
1. A sheet material comprising:
a scrim layer having a first side and a second side;
a first layer of polymer having an inner side and an outer side, said inner side of said first layer being bonded to said first side of said scrim layer;
and a second layer of polymer having an inner side and an outer side, said inner side of said second layer being bonded to said second side of said scrim layer.
a scrim layer having a first side and a second side;
a first layer of polymer having an inner side and an outer side, said inner side of said first layer being bonded to said first side of said scrim layer;
and a second layer of polymer having an inner side and an outer side, said inner side of said second layer being bonded to said second side of said scrim layer.
2. A sheet material according to claim 1, wherein said outer side of said first and second polymer layers have a textured surface adapted to resemble leather.
3. A sheet material according to claim 1, wherein said first and second polymer layers are vinyl.
4. The material of claim 1 wherein the total thickness is from 0.03 to 0.05 inches.
5. A sheet material as in claim 1 wherein said first and second polymer layers are polyester.
6. A sheet material of claim 1 wherein said scrim is selected from the group consisting of woven, nonwoven and knitted fabrics.
7. A sheet material of claim 1 wherein the scrim is a knitted fabric.
8. A sheet material of claim 7 wherein said first and second polymer layers are vinyl.
9. A curtain for a truck operator compartment comprising:
a pliable single laminar sheet formed by a scrim layer sandwiched between a first pliable polymer layer and a second pliable polymer layer;
said first polymer layer having a first inner side and a first exposed side, said first inner side being integrally formed upon a first side of said scrim layer; and said second polymer layer having a second inner side and a second exposed side, said second inner side being integrally formed upon a second side of said scrim layer, said second side of said scrim layer being opposite of said first side of said scrim layer.
a pliable single laminar sheet formed by a scrim layer sandwiched between a first pliable polymer layer and a second pliable polymer layer;
said first polymer layer having a first inner side and a first exposed side, said first inner side being integrally formed upon a first side of said scrim layer; and said second polymer layer having a second inner side and a second exposed side, said second inner side being integrally formed upon a second side of said scrim layer, said second side of said scrim layer being opposite of said first side of said scrim layer.
10. A curtain in accordance with claim 9, wherein the thickness of said sheet is from 0.03 to 0.05 inches.
11. A curtain in accordance with claim 10 wherein said first and second polymer layers are vinyl.
12. A curtain in accordance with claim 10 wherein said first and second layers are polyester.
13. A curtain in accordance with claim 9, wherein scrim is a knitted fabric.
14. A method of producing a single laminar sheet of material having a scrim layer sandwiched between a first polymer layer and a second pliable polymer layer, comprising the steps of:
(a) providing a layer of scrim having a first and second side;
(b) depositing a first polymer layer on said first side of said scrim layer; and (c) depositing a second polymer layer on said second side of said scrim layer to create said laminar sheet.
(a) providing a layer of scrim having a first and second side;
(b) depositing a first polymer layer on said first side of said scrim layer; and (c) depositing a second polymer layer on said second side of said scrim layer to create said laminar sheet.
15. A method in accordance with claim 14, wherein said polymer is vinyl.
16. A method in accordance with claim 14, wherein said polymer is polyester.
17. A method of claim 14 wherein said scrim is a knitted fabric.
18. A method of claim 17 wherein said first and second polymer layers are polyester.
19. A method of claim 17 wherein said first and second polymer layers are vinyl.
20. A method of claim 14 wherein said scrim is a nonwoven fabric.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US49180300A | 2000-01-26 | 2000-01-26 | |
| US09/491,803 | 2000-01-26 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2297699A1 true CA2297699A1 (en) | 2001-07-26 |
Family
ID=23953737
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2297699 Abandoned CA2297699A1 (en) | 2000-01-26 | 2000-02-03 | Double-sided polymer laminar sheet and use |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2297699A1 (en) |
-
2000
- 2000-02-03 CA CA 2297699 patent/CA2297699A1/en not_active Abandoned
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| CN101992732B (en) | Flat seam construction for automotive upholstery | |
| US8579347B2 (en) | Seam spacers for use with decorative stitching of vehicle interior components | |
| US6808786B2 (en) | Automotive tufted carpet with enhanced acoustical properties | |
| KR0185703B1 (en) | Method for producing a multilayered web for upholstery cover material for vehicles | |
| EP1565310B1 (en) | Barrier fabric | |
| DE102019110909A1 (en) | Spacer fabrics | |
| DE102005037572A1 (en) | Covering part, in particular Innenverkleidungs- or lining part for motor vehicles | |
| US3671984A (en) | Upholstery edging | |
| EP2689691B1 (en) | Seat structure | |
| DE69117790T2 (en) | Stretchable composite and process with covering properties and its application | |
| JP2023165696A (en) | Decoration nonwoven fabric laminate | |
| DE102019110908A1 (en) | Composite arrangement | |
| Mukhopadhyay et al. | Automotive textiles | |
| CN1209238C (en) | Composite for use in manufacture of transportation vehicle seating trim | |
| DE102009006985A1 (en) | Cover e.g. seat cover, for covering part of base body of e.g. seat of car, has dimensionally stable contour reproducing individual shape of equipment part to be covered by three-dimensional deformation of cover | |
| US20150147517A1 (en) | Textile fabric, use and production of a textile fabric and furniture element | |
| CA2297699A1 (en) | Double-sided polymer laminar sheet and use | |
| US8778818B2 (en) | Anti-vandalism fabric suitable for upholstering seats | |
| DE102012219123B4 (en) | Production process for decor material with pipe optics and corresponding decorative material | |
| US5680826A (en) | Shoe-wiping mat for rent | |
| CA2588016A1 (en) | Mattress construction with filamentary fasteners | |
| JP6660648B1 (en) | Skin material | |
| US5851934A (en) | Composite curtain | |
| EP3604031B1 (en) | Cover attachment for attaching a seat cover | |
| JPS6124437A (en) | Sheet material |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| FZDE | Dead |