KR20020000767A - Silicone coated fluid shield fabric - Google Patents

Abstract

In some cases fabrics are provided that have washable and fluid resistant properties that can be transfer imprinted. This fabric comprises a fabric substrate treated with a fluorine stain inhibitor. The treated textile substrate is substantially covered on the back with a layer of coated silicone polymer. Also provided is a method of forming a fluid shielding fabric according to the present invention.

Description

Silicone Coated Fluid Shielding Fabric {SILICONE COATED FLUID SHIELD FABRIC}

In the past, many attempts have been made to impart washability and liquid resistance to fabrics to make them more useful in environments where liquid staining is likely to occur. Vinyl coated fabrics have been most widely accepted for this purpose because of their relatively easy cleanability and very low cost. However, such vinyl coated fabrics have typically been considered poor in appearance and feel for use in environments where it is stiff to provide a user with a satisfactory feel and visual perception, such as restaurants, nursing homes and the like. Surface-laminated fabrics have been used for the purpose of improving the aesthetic properties of the fabrics, but such fabrics are delaminated, cracked, and laminated after prolonged use due to the general adhesion properties between the laminate film and the fabric itself. It tends to decompose. Such laminated products also tend to have a poor texture that is generally desirable for standard upholstery products. Anti-staining treatments with fluorochemcals make it much more difficult to attach the liquid barrier film or coating to the fabric substrate because the composition used tends to repel the coating being applied.

In accordance with the present invention, a strong adhesive fluid is obtained by appropriately selecting the base fabric and its coating in such a way that the stain resistant properties imparted by the fluorine compound and the very thin layer of barrier material (preferably less than 2 oz / yd ² ) are applied. Providing the blocking shielding ability overcomes the above-mentioned appearances which conflict with each other. The material that actually constitutes the barrier layer preferably possesses elastomeric properties and dyeability that tend to be substantially compliant to the fabric substrate. Thus, according to the present invention, useful technical advances over the prior art have been achieved.

This application is a partial consecutive application of U.S. Patent Application Serial No. 08 / 799,790, filed February 12, 1997, entitled “FLUID SHIELD FABRIC,” which is a prior application owned and co-pending.

The present invention relates to upholstery fabrics, more particularly fabrics having antimicrobial and stain resistant properties in combination with fluid barrier coatings suitable for transfer printing without adversely affecting the feel of the fabric. Also provided is a method of forming the fabric in accordance with the present invention.

In view of the foregoing, it is intended to provide a fabric that not only retains both anti-stain and fluid barrier properties, which is a general object of the present invention, but also exhibits the same soft fabric feel as in conventional untreated upholstery fabrics. By means should be understood to mean having the same flexibility as the actual fabric and / or reduced rigidity.

More particularly, the present invention seeks to provide a fabric in which a barrier coating of polymeric material is attached in a stable relationship to a surface treated with a fluorine compound.

More particularly, the present invention provides an upholstery fluid shielding fabric having a barrier coating of silicone polymer material in a stable relationship to a surface treated with a fluorine compound of a woven, knitted or nonwoven fabric substrate.

Other objects, advantages and features of the present invention will be apparent to those skilled in the art through the following discussion. Thus, while the invention has been described or disclosed in combination with certain preferred embodiments and processes, these specific embodiments and processes should not be construed as limiting the invention. In addition, the invention is to be construed as including all alternative embodiments, processes and variations that fall within the spirit and scope of the invention and its equivalents as defined by the claims appended hereto.

Provided is a fluid shielding fabric that can be transfer printed. The fabric exhibits a good feel while maintaining a close adhesion between the base fabric and the polymeric barrier material despite the intermediate use of the composition of the fluorine compound.

In a potentially preferred implementation of the present invention, the fabric substrate is treated with a fluorochemical stain inhibitor, and then coated substantially on the backside (ie, unprinted surface) with a layer of polymeric material to provide both fluid and stain resistant properties. Obtain the final structure shown.

The fabric substrate is preferably a woven fabric, but the densely formed knitted materials and / or nonwovens known to those skilled in the art may also be used if desired. Such fabric substrates are preferably formed from polyester yarns, although other materials can also be used, including, for example, cotton-polyester blends, nylon and polypropylene, but the invention is not so limited.

In one particularly preferred embodiment, when using a calendering process to planarize the fabric on the side being coated, the amount of polymeric material required for the knife coating to achieve the desired barrier properties in application of the polymeric material across the woven fabric substrate. It was found to reduce. It has also been found that through the use of suitable silicone polymers a high degree of flexibility can be achieved without the occurrence of cracks. Preferred coating materials include PDMS silicone compositions sold by Walker Chemical, Adrian, Mich., Including crosslinking agents and inhibitors, for example as bicomponent kits under the trade names LR3003-10A and B.

Using a fabric woven tightly with Albi Yarn improves adhesion between the fabric substrate and the polymeric material. The polymeric material has this property for carrying out thermal transfer printing at temperatures between 350 ° F. and 450 ° F. without damaging the polymeric coating. The invention can also be understood and illustrated with reference to the following non-limiting examples.

Example 1

The following examples describe the preparation of fabrics according to the invention intended for dyeing applications.

A woven fabric with a weave density of about 68 ends / in × 46 picks / in was formed from a 2-ply woven Albi polyester yarn to obtain a 100% plain woven polyester woven fabric. The fabric was rubbed in a bath at 180-200 ° F., pH 7-8. The fabric was then about 1% to 40% fluorine compound, such as MILLIGUARD® BK96, a fluoroacrylate copolymer emulsion from Milliken Chemical, Spartanburg, South Carolina; ULTRA-FRESH® NM about 0.5% to 5.0% (preferably about 3.0%); Ultra Fresh (R) 40 from about 0.05% to 1.0% (preferably about 1.0%) available from Thompson Research; And an antistatic agent such as Antistat 993, an ester salt from Sybron Chemical, Wellford, South Carolina, containing 0.5% to 5.0% (preferably 3.0%) Padded with 50% pick-up.

In a preferred implementation this solution comprises both antibacterial and antistatic components, but it is believed and recognized that one or more of these additional components may optionally be excluded. After padding application of this preparation solution, the fabric is cured at a temperature of about 225 ° F. to 425 ° F., preferably about 350 ° F., for 60 seconds. Thereafter, the woven fabric substrate to which the fluorochemical stain inhibitor is applied passes through a calendering operation to planarize one or more sides of the fabric. The calendering operation is preferably performed at a pressure of about 200 N / mm with a calendering roll temperature of about 392 ° F.

In a preferred implementation, the PDMS silicone composition is knife coated across the calendered surface of the fabric to form an effective barrier layer. The surface for application is preferably calendared, but this may also not be calendared.

In a preferred implementation, the total amount of barrier layer applied is less than about 2 oz / yd ² , preferably less than about 1.5 oz / yd ² , most preferably about 0.8 to 1.2 oz / yd ² .

After the coating process, the fabric is then passed through an oven to fix the silicon barrier layer. This operation is preferably performed at a temperature of about 390 ° F. for about 80 seconds.

It is contemplated that additional performance enhancing components may be incorporated into polymeric materials that are coated onto the fabric substrate. Such performance enhancing components are merely non-limiting examples of antimicrobial compositions known to those skilled in the art; Flame retardants, antistatic agents and / or ultraviolet stabilizers.

In view of the above disclosure of potentially preferred embodiments and processes, it will be appreciated that the general principles of the invention disclosed herein may be applied in a variety of ways. Accordingly, it is contemplated to include any of the above variations and other aspects that incorporate the features of the invention within the broadest acceptable scope by the appended claims.

Claims (15)

A fluid shield fabric comprising a fabric substrate, a fluorine stain inhibitor substantially covering the fabric substrate, and a thermoset silicone layer substantially covering the fabric to provide a barrier to liquid passage. The method of claim 1, A fluid shielding fabric wherein the fabric substrate is polyester. The method of claim 1, A fluid shielding fabric wherein the fabric substrate is nylon. The method of claim 1, A fluid shielding fabric wherein the fabric substrate is polypropylene. The method of claim 1, A fabric for fluid shielding wherein the fabric substrate is a woven fabric. The method of claim 1, A fluid shielding fabric wherein the fabric substrate is a knit fabric. The method of claim 1, A fluid shielding fabric wherein the fabric substrate is a nonwoven fabric. The method of claim 1, A fluid shielding fabric, wherein the fabric substrate comprises a smoothly calendered surface. The method of claim 1, A fluid shielding fabric further comprising a flame retardant disposed across the fabric substrate. The method of claim 1, A fluid shielding fabric further comprising an antimicrobial agent disposed across the fabric substrate. The method of claim 1, A fluid shielding fabric comprising a flame retardant with silicone disposed therein. The method of claim 1, A fluid shielding fabric, wherein the silicone comprises an ultraviolet stabilizer disposed therein. The method of claim 1, A fluid shielding fabric, wherein the silicone comprises an antimicrobial agent disposed therein. The method of claim 1, A fluid shielding fabric, wherein the silicone comprises an antistatic agent disposed therein. The method of claim 1, A fluid shielding fabric wherein silicone is present in an amount of about 2 oz / yd ² or less.