GB2235651A - Composite article - Google Patents

Composite article Download PDF

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Publication number
GB2235651A
GB2235651A GB9015583A GB9015583A GB2235651A GB 2235651 A GB2235651 A GB 2235651A GB 9015583 A GB9015583 A GB 9015583A GB 9015583 A GB9015583 A GB 9015583A GB 2235651 A GB2235651 A GB 2235651A
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GB
United Kingdom
Prior art keywords
composite article
article according
cloth
microfibrous
woven material
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.)
Granted
Application number
GB9015583A
Other versions
GB9015583D0 (en
GB2235651B (en
Inventor
Bucci Cesare Di
Carlo Borri
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.)
Alcantara SpA
Original Assignee
Alcantara SpA
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Filing date
Publication date
Application filed by Alcantara SpA filed Critical Alcantara SpA
Publication of GB9015583D0 publication Critical patent/GB9015583D0/en
Publication of GB2235651A publication Critical patent/GB2235651A/en
Application granted granted Critical
Publication of GB2235651B publication Critical patent/GB2235651B/en
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

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Classifications

    • 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
    • B32B5/245—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 being a foam 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
    • 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
    • B32B5/026—Knitted 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
    • B32B5/18—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 features of a layer of foamed material
    • 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
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4326—Condensation or reaction polymers
    • D04H1/435—Polyesters
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
    • D04H1/64—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions
    • D04H1/68—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions the bonding agent being applied in the form of foam
    • 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
    • D06N3/0002—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate
    • D06N3/0015—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate using fibres of specified chemical or physical nature, e.g. natural silk
    • 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
    • D06N3/0043—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by their foraminous structure; Characteristics of the foamed layer or of cellular layers
    • 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
    • D06N3/12—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins
    • D06N3/14—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins with polyurethanes
    • 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
    • B32B2262/0261—Polyamide 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
    • B32B2262/0276—Polyester 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
    • B32B2262/0276—Polyester fibres
    • B32B2262/0284—Polyethylene terephthalate [PET] or polybutylene terephthalate [PBT]
    • 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
    • B32B2262/062—Cellulose fibres, e.g. cotton
    • 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
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/0221—Vinyl resin
    • B32B2266/0228—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
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/025—Polyolefin
    • 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
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/0278—Polyurethane
    • 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
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/306—Resistant to heat
    • B32B2307/3065—Flame resistant or retardant, fire resistant or retardant
    • 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
    • B32B2605/00—Vehicles
    • B32B2605/003—Interior finishings
    • 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
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
    • B60R13/02—Internal Trim mouldings ; Internal Ledges; Wall liners for passenger compartments; Roof liners

Abstract

A composite article useful for decorating walls and coating the interior of transport means such as cars and boats, comprises an outer layer of a microfibrous, non-woven fabric, and an inner layer of a foamed plastic material. The microfibrous non-woven material may be a material consisting of microfibres of a polyester or a polyamide in a polyurethane matrix. A waterproofing may be connected to the layer of foamed material. The composite article may comprise in the following orders, layers of (1) (a) microfibrous non-woven material (b) foamed plastic material (c) cloth, of (2) (a) microfibrous non-woven material (b) foamed plastic material and (c) knitted fabric of (3) (a) microfibrous non-woven material (b) knitted fabric (c) foamed plastic material and (d) knitted fabric, (4) (a) microfibrous non-woven material (b) cloth, (c) foamed plastic material and (d) cloth and (5) (a) microfibrous non-woven material (b) cloth (c) foamed plastic material and (d) knitted fabric.

Description

"COMPOSITE ARTICLE The present invention relates to a composite article comprising a layer of a microfibrous, non-woven material, useful in the field of interior or decor at ion and of coating.
Microfibrous, non-woven materials, constituted by polyester or polyamide microfibres, e.g., microfibres of nylon-6, in a polyurethane matrix, are known in the art.
Among these materials, the one formed by poly-(ethylene terephthalate) microfibres in a polyurethane matrix constitutes a valuable, widely used, product, used in particular in garment industry, thanks to its excellent characteristics of appearance, pleasant hand, lightweight, velours and to its fastness to light and to nitrogen oxides in the atmosphere.
According to the instant finding, such microfibrous, non-woven materials are coupled with a layer of a foamed plastic material in order to supply novel composite materials in which an extremely good aesthetical appearance is combined with characteristics which render the same composite materials suitable for use in the sector of interior decoration, and in the sector of coating.
In accordance therewith, the present invention relates to a composite article particularly useful for decorating walls and for coating the interior of transport means, such as cars and boats, which comprises an outer layer of a micro fibrous, non-woven fabric, and an inner layer of a foamed plastic material.
In the instant invention, by the term "microfibres" those fibres are meant which have a count comprised within the range of from 0.01 deniers to 0.40 deniers, and preferably of the order of from 0.08 to 0.15 deniers.
The microfibrous, non-woven material formed by microfibres of poly-tethylene terephthalate) in polyurethane can be obtained by means of a process generally comprising the following steps: * a non-woven fabric made from microfibres of poly (ethylene terephthalate) is impregnated with a polyurethanic elastomer; * said polyurethanic elastomer is coagulated in order to form a composite, microfibrous sheet; * said composite, microfibrous sheet is ground in order to form a raw, microfibrous, non-woven fabric; and * said raw, microfibrous, non-woven fabric is dyed in order to produce a dyed end product.
The non-woven fabric of microfibres of poly (ethylene terephthalate) can be obtained in its turn from a raw felt of staple fibre, constituted by microfibres of poly-tethylene terephthtalate) in a polystyrene matrix, with said raw felt being submitted to needling in order to produce a needled felt, with said needled felt being treated first with -an åqueous- sotution of poLyvinyl alcohol and then with perchloroethylene, so as to dissolve the polystyrene matrix and recover the non-woven fabric of microfibres of poly-tethylene terephthalate).
The microfibrous, non-woven material obtained in that way shows excellent characteristics of appearance, hand, light-weight, velours, fastness to light and to nitrogen oxides in the atmosphere.
In particular, such a non-woven, microfibrous material displays characteristics generally falling inside the following range of values: * thickness (ASTM D-1910) : from 0.6 to 0.9 mm * weight per unit surface area : from 170 to 250 g/m2 * tenacity (ASTM D-1682) longitudinal : from 5.0 to 9.0 kg/cm transversal : from 3.0 to 6.0 kg/cm * elongation at breakage (ASTM D-1682) longitudinal : from 65 to 80% transversal . from 110 to 130% * tearing strength according to Elmendorf longitudinal . from 2.3 to 1.5 kg transversal : from 1.3 to 0.7 kg * fastness to light (80 SHF; grays scale; AATCC 16A 1964) : from 6 to 7 * fastness to atmospheric nitrogen oxides (1 cycle;AATCC 23 1975) : from 3 to 5 According to the present invention, such a microfibrous, non-woven material, or similar microfibrous, non-woven materials, is(are) coupled with a layer of a foamed plastic material in order to produce novel materials, usesul in the above set forth sectors.
More particularly, according to a form of practical embodiment of the present invention, the microfibrous, non-woven material is coupled with a foamed plastic material by means of a flame treatment, or by means of the interposition of a bonding agent.
The foamed plastic materials useful for the intended purpose can be selected from within a wide class of materials, such as, e.g., polyurethanes, polyethers, polyolefins and polystyrene. As a general rule, the thickness of the layer of the foamed material can be comprised within the range of from 2 to 10 mm, and the foamed material may be endowed with flame-retardant characteristics, it may be heat-welding, or it may be or may be not provided with an adhesive layer, whether desired or necessary, as a function of the particular use it is intended for. The soys obtained composite articles are suitable for decorating walls, or for coating the interior of transport means, e.g., for coating the inner surfaces of the decks of cars, and the surfaces of boat interiors.In these applications, the articles according to the present invention display very good deadening properties, touch and pleasant hand characteristics.
According to another form of practical embodiment of the present invention, on the back face of the microfibrous, non-woven material a polyurethane emulsion is spread by means of a doctor, in order to manufacture rigid composite articles. According to a further technique, a polyurethane foam is flame-coupled with a layer of a microfibrous, non-woven material and with a waterproofing fiLm, ln order-to obtain soft composite articles, in which the thickness of the polyuretane layer is of the order of from 2 to 8 mm. In any case, the obtained articles are suitable for coating the inner walls of interiors of cars, such as decks, doors and dashboards.
According to still another form of practical embodiment, the microfibrous, non-woven material is coupled with a cloth by means of the "multid3t" system, and the so obtained product is flame-coupled with a polyurethane foam, with a thickness comprised within the range of from 2 to 10 mm, and then with a light knitted cloth. Also in this case, composite articles are obtained, which are useful for inner coatings for cars.
Still other examples of composite articles, according to the present invention, are constituted by: * microfibrous, non-woven material 1 foamed plastic material I cloth; * microfibrous, non-woven material / foamed plastic material / light knitted fabric; * microfibrous, non-woven material / light knitted fabric / foamed plastic material / light knitted fabric; and * microfibrous, non-woven material / cloth / foamed plastic material I cloth.
The cloths can be made from cotton, polyester, nylon fibres or blended fibres, and one or more component(s) of the composite material can be endowed with flameretarding characteristics. Furthermore, the microfibrous, non-woven material can be perforated, sewn, shorn, printed or embossed.
In the following experimental examples, as the microfibrous, non-woven material the product available from the market is used, which is traded under the name MASTER-COVER (registered mark) by the company ALCANTARA, and has the following characteristics: * thickness . from 0.6 to 0.9 mm * weight per unit surface area : fro 170 to 230 gSm2 * tenacity longitudinal . from 5.0 to 9.0 kg/cm transversal : from 3.0 to 6.0 kg/cm * elongation longitudinal : from 65 to 80% transversal : from 110 to 130' * fastness to light : from 6 to 7 * fastness to nitrogen oxides : from 3 to 5 Furthermore, such a synthetic microfibrous product 'shows a nice appearance, a thick and natural velours and a fault-free dyeing ability.
Example 1 In a first test, the microfibrous, non-woven material having the characteristics reported in the disclosure is flame-coupled with a layer of a foamed polyurethane, of 3 to 6 mm of thickness. In a second test, on the back face of the microfibrous, non-woven material a bonding agent is spread by means of a doctor, the material is coupled with a layer of foamed polyurethane of the above detailed type, and the so obtained composite material is made pass through a calender and then is dried in an air-oven. In both cases, a composite article is obtained, which has a nice appearance, shows deadening properties, touch and a pleasant hand. It is particularly useful for decorating walls, and for coating the interior of transport nears, in particular of boats.
Ex~mpl~~2 In a first test, on the back face of the microfibrous, non-woven material a polyurethane emulsion is spread by means of a three-heads spreading machine, so as to form a film of from 30 to 80 gIm2 . In a second test, a polyurethane foam of from 3 to 6 mm and with a density of 28-50 kg/m3 is flame coupLed; on one face, with the microfibrous, non-woven material, and on the other face with an waterproofing polyurethane film. In that way, composite articles are obtained, which are useful in the production of respectively rigid and soft components suitable for coating the interior oi cars.
Example 3 The microfibrous, non-woven material is coupled by means of the multidot system with a mixed cottonpolyester cloth. This composite material is then processed on a double-head flame-coupling machine. During the passage on the first head, said material is coupled with a polyurethane foam having a thickness of 3-6 mm and a density of 24-50 kglm3, and on the second head it is flame-coupled with a light knitted fabric of poly (ethylene terephtalate) endowed with elastic properties along both longitudinal and transversal directions (i.e., a bi-elastic knitted fabric). The composite material can be used for applications similar to those as of Example 2.

Claims (15)

1. A composite article comprising an inner layer of a foamed material and an outer layer of a microfibrous non-woven material.
2. A composite article according to claim 1, wherein the microfibrous non-woven material comprises polyester microfibres or polyamide microfibres in a polyurethane matrix.
3. A composite article according to claim 2, wherein the polyester microfibres are poly(ethylene terephthalate) microfibres.
4. A composite article according to claim 2, wherein the polyamide microfibres are nylon-6 microfibres.
5. A composite article according to any of claims 1 to 4, wherein the foamed material is a polyurethane foam, a polyether foam, a polyolefin foam or a polystyrene foam.
6. A composite article according to any of claims 1 to 5, further comprising a waterproofing film connected to the layer of foamed material.
7. A composite article according to claim 1, comprising layers of (a) microfibrous non-woven material, (b) foamed plastic material and (c) cloth, in the order given.
8. A composite article according to claim 1, comprising layers of (a) microfibrous non-woven material, (b) foamed plastic material and (c) knitted fabric, in the order given.
9. A composite article according to claim 1, comprising layers of (a) microfibrous non-woven material, (b) knitted fabric, (c) foamed plastic material, and (d) knitted fabric, in the order given.
10. A composite article according to claim 1, comprising layers of (a) microfibrous non-woven material, (b) cloth, (c) foamed plastic material and (d) cloth, in the order given.
11. A composite article according to claim 1, comprising layers of (a) microfibrous non-woven material, (b) cloth, (c) foamed plastic material and (d) knitted fabric, and the order given.
12. A composite article according to any of claims 7, 10 and 11, wherein the cloth is a cotton cloth, a polyester cloth, a nylon cloth or a mixed cloth.
13. A composite article according to any of claims 1 to 12, wherein the microfibrous non-woven material is perforated, sewn, shorn, printed or embossed.
14. A composite article according to any of claims 1 to 13, wherein one or more of the components thereof has flame-retardant characteristics.
15. A composite article according to claim 1, substantially as described in any of the foregoing Examples.
GB9015583A 1989-07-19 1990-07-16 Composite article Expired - Fee Related GB2235651B (en)

Applications Claiming Priority (1)

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IT8921458U IT216763Z2 (en) 1989-07-19 1989-07-19 COUPLED ITEM, INCLUDING A LAYER OF MICROFIBROUS NON-WOVEN MATERIAL, USEFUL IN THE FURNISHING AND COATING SECTOR.

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GB9015583D0 GB9015583D0 (en) 1990-09-05
GB2235651A true GB2235651A (en) 1991-03-13
GB2235651B GB2235651B (en) 1993-12-22

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Publication number Priority date Publication date Assignee Title
EP0786333A1 (en) 1995-12-18 1997-07-30 ALCANTARA S.p.A. Composite product consisting of a leather-like microfibrous material and polymer film, useful for coating cold injection molding manufactured articles
WO1998036900A1 (en) * 1997-02-21 1998-08-27 Möller Plast GmbH Multi-layer composite body
WO1999044817A1 (en) * 1998-03-03 1999-09-10 Rieter Automotive (International) Ag Sound absorbent thin-layer laminate
CH692780A5 (en) * 1998-03-03 2002-10-31 Rieter Automotive Int Ag Sound absorbent thin layer laminate useful for noise reduction in motor vehicles
CH693409A5 (en) * 1998-11-12 2003-07-31 Rieter Automotive Int Ag Sound absorbent thin layer laminate useful for noise reduction in motor vehicles
WO2012107893A1 (en) 2011-02-10 2012-08-16 Alcantara S.P.A. Process for garment dyeing of an article comprising a microfibrous non woven fabric
JP2020506086A (en) * 2017-01-26 2020-02-27 アルカンタラ、ソシエタ、ペル、アチオニＡｌｃａｎｔａｒａ Ｓ．Ｐ．Ａ． Multi-fiber multilayer composites for automotive applications

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DE4224667C2 (en) * 1992-07-25 1997-01-09 Helmut Pelzer Production of a multi-layer wall covering
DE4409329A1 (en) * 1994-03-18 1995-09-21 Hartmann Paul Ag Composite material for sound and heat insulation
US20110305865A1 (en) * 2009-03-04 2011-12-15 Dow Global Technologies Inc. (Formerly Known as Dow Global Technologies Inc.) Sound-dampening polyurethane-based composite

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GB1329710A (en) * 1969-07-09 1973-09-12 Toray Industries Leather substitute and a method of manufacturing the same
GB1455374A (en) * 1973-02-17 1976-11-10 Kuraray Co Porous sheet materials and a method for manufacturing them
US4681798A (en) * 1984-12-24 1987-07-21 Manville Service Corporation Fibrous mat facer with improved strike-through resistance

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Publication number Priority date Publication date Assignee Title
GB1329710A (en) * 1969-07-09 1973-09-12 Toray Industries Leather substitute and a method of manufacturing the same
GB1455374A (en) * 1973-02-17 1976-11-10 Kuraray Co Porous sheet materials and a method for manufacturing them
US4681798A (en) * 1984-12-24 1987-07-21 Manville Service Corporation Fibrous mat facer with improved strike-through resistance

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0786333A1 (en) 1995-12-18 1997-07-30 ALCANTARA S.p.A. Composite product consisting of a leather-like microfibrous material and polymer film, useful for coating cold injection molding manufactured articles
WO1998036900A1 (en) * 1997-02-21 1998-08-27 Möller Plast GmbH Multi-layer composite body
WO1999044817A1 (en) * 1998-03-03 1999-09-10 Rieter Automotive (International) Ag Sound absorbent thin-layer laminate
CH692780A5 (en) * 1998-03-03 2002-10-31 Rieter Automotive Int Ag Sound absorbent thin layer laminate useful for noise reduction in motor vehicles
CH693409A5 (en) * 1998-11-12 2003-07-31 Rieter Automotive Int Ag Sound absorbent thin layer laminate useful for noise reduction in motor vehicles
WO2012107893A1 (en) 2011-02-10 2012-08-16 Alcantara S.P.A. Process for garment dyeing of an article comprising a microfibrous non woven fabric
JP2020506086A (en) * 2017-01-26 2020-02-27 アルカンタラ、ソシエタ、ペル、アチオニＡｌｃａｎｔａｒａ Ｓ．Ｐ．Ａ． Multi-fiber multilayer composites for automotive applications

Also Published As

Publication number Publication date
GB9303683D0 (en) 1993-04-14
IT8921458V0 (en) 1989-07-19
GB9015583D0 (en) 1990-09-05
IT216763Z2 (en) 1991-10-03
GB2262710B (en) 1993-12-22
FR2649933B3 (en) 1991-06-21
FR2649933A3 (en) 1991-01-25
GB2262710A (en) 1993-06-30
GB2235651B (en) 1993-12-22
DE9010788U1 (en) 1990-09-27

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