US4034134A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Laminates and coated substrates
Assignee: United Merchants and Manuf Inc
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Filing: 1975-10-07
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Granted: 1977-07-05
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Expires: 1995-10-07
Abstract
Abstract A process for producing a laminate by coating a continuous first layer of a film forming material onto a release sheet, distributing flock fibers uniformly onto the first layer, drying the first layer to form a film and secure the flock fibers thereto in a substantially upstanding position, coating the tips of the flock fibers with a flock adhesive, marrying the flocked film to a substrate backing layer such that the coated tips contact the said substrate layer, permanently setting the flock adhesive, and then removing the release sheet. Laminates obtained by such method are also described.
Inventors
- 👤 Razmic S. Gregorian
- 👤 Hans R. Hoernle
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-30 14:58
CPC Classifications
B; B05; B05D; B05D1/00; B05D1/16; B05D1/28; B05D1/286; Y; Y10; Y10T; Y10T156/00; Y10T156/11; Y10T156/1168; Y10T156/1195; Y10T428/00; Y10T428/23907; Y10T428/23914; Y10T428/23921; Y10T428/23979; Y10T428/23986; Y10T428/23993
Claims Analysis
Total Claims: 32
Claim 1
Independent Claim
105 words
A laminate comprising: (a) an air permeable film facing layer; and (b) a substrate backing layer secured to the facing layer by a plurality of uniformly distributed, substantially upstanding flock fibers, one end of substantially all of the flock fibers being permanently embedded in the facing layer and the other end of substantially all of the flock fibers being secured to the substrate backing layer by a discontinuous layer of a flock adhesive and wherein substantially all of the flock adhesive is present at the tips of the flock fibers which are secured to the substrate backing layer, thereby imparting air permeability to the laminate.
Claim 2
Dependent Claim
105 words
A laminate comprising: (a) an air permeable film facing layer; and (b) a substrate backing layer secured to the facing layer by a plurality of uniformly distributed, substantially upstanding flock fibers, one end of substantially all of the flock fibers being permanently embedded in the facing layer and the other end of substantially all of the flock fibers being secured to the substrate backing layer by a discontinuous layer of a flock adhesive and wherein substantially all of the flock adhesive is present at the tips of the flock fibers which are secured to the substrate backing layer, thereby imparting air permeability to the laminate.
Claim 3
Dependent Claim
11 words
The laminate of claim 1 wherein the facing layer is decorative.
Claim 4
Dependent Claim
19 words
The laminate of claim 2 wherein the facing layer has particulate material substantially embedded in its outer exposed surface.
Claim 5
Dependent Claim
18 words
The laminate of claim 2 wherein the facing layer has particulate material on the outer, exposed surface thereof.
Claim 6
Dependent Claim
27 words
The laminate of claim 1 wherein the facing layer is a flexible film of a material selected from the group consisting of urethanes, vinyls, nitriles and acrylics.
Claim 7
Dependent Claim
35 words
The laminate of claim 1 wherein the flock fibers are composed of materials selected from the group consisting of rayon, cotton, nylon, polyester, wool, mohair, silk, acrylic, modacrylic, natural and synthetic fibers, and blends thereof.
Claim 8
Dependent Claim
24 words
The laminate of claim 1 wherein the flock adhesive is selected from the group consisting of urethane, vinyl, neoprene, acrylic, vinyl-acrylic, and styrene-butadiene latexes.
Claim 9
Dependent Claim
17 words
The laminate of claim 1 wherein the substrate backing layer is a woven, knitted, or non-woven fabric.
Claim 10
Dependent Claim
15 words
The laminate of claim 1 wherein the substrate backing layer is a sliver knit fabric.
Claim 11
Dependent Claim
21 words
The laminate of claim 1 wherein the substrate backing material is selected from the group consisting of natural and synthetic fibers.
Claim 12
Dependent Claim
86 words
An air permeable laminate comprising: (a) a continuous film facing layer; and (b) a substrate backing layer secured to the facing layer by a plurality of uniformly distributed, substantially upstanding flock fibers, one end of substantially all of the flock fibers being permanently embedded in the facing layer, and the other end of substantially all of the flock fibers being secured to the substrate backing layer by a flock adhesive wherein substantially all of the flock adhesive is present at the tips of the flock fibers.
Claim 13
Dependent Claim
86 words
An air permeable laminate comprising: (a) a continuous film facing layer; and (b) a substrate backing layer secured to the facing layer by a plurality of uniformly distributed, substantially upstanding flock fibers, one end of substantially all of the flock fibers being permanently embedded in the facing layer, and the other end of substantially all of the flock fibers being secured to the substrate backing layer by a flock adhesive wherein substantially all of the flock adhesive is present at the tips of the flock fibers.
Claim 14
Dependent Claim
94 words
A process for producing a laminate comprising: (a) coating a release sheet with a continuous first layer of a film forming material; (b) distributing flock fibers uniformly onto the first layer; (c) drying the first layer to form a film and securing the flock fibers thereto in a substantially upstanding position; (d) coating the tips of the flock fibers with a flock adhesive; (e) marrying the flocked fibers to a substrate backing layer such that the coated tips contact the substrate layer; (f) permanently setting the flock adhesive; and (g) removing the release sheet.
Claim 15
Dependent Claim
94 words
A process for producing a laminate comprising: (a) coating a release sheet with a continuous first layer of a film forming material; (b) distributing flock fibers uniformly onto the first layer; (c) drying the first layer to form a film and securing the flock fibers thereto in a substantially upstanding position; (d) coating the tips of the flock fibers with a flock adhesive; (e) marrying the flocked fibers to a substrate backing layer such that the coated tips contact the substrate layer; (f) permanently setting the flock adhesive; and (g) removing the release sheet.
Claim 16
Dependent Claim
22 words
The process of claim 12 wherein the film forming material is selected from the group consisting of urethanes, vinyls, nitriles and acrylics.
Claim 17
Dependent Claim
13 words
The process of claim 12 wherein the release sheet possesses a smooth surface.
Claim 18
Dependent Claim
13 words
The process of claim 12 wherein the release sheet possesses a textured surface.
Claim 19
Dependent Claim
42 words
The process of claim 12 wherein the release sheet possesses particulate material on the surface thereof and wherein the particulate material is substantially embedded into the first layer in step (a) as a result of the viscosity of the film forming material.
Claim 20
Dependent Claim
21 words
The process of claim 16 wherein the viscosity of the film forming material is from about 20,000 to about 80,000 cps.
Claim 21
Dependent Claim
44 words
The process of claim 12 wherein the release sheet possesses particulate material on the surface thereof and wherein the particulate material is retained on the surface of the first layer during step (a) as a result of the viscosity of the film forming material.
Claim 22
Dependent Claim
21 words
The process of claim 18 wherein the viscosity of the film forming material is from about 100,000 to about 300,000 cps.
Claim 23
Dependent Claim
11 words
The process of claim 12 wherein the first layer is decorative.
Claim 24
Dependent Claim
20 words
The process of claim 12 wherein the flock fibers have a length of from about 1/2 to about 5 millimeters.
Claim 25
Dependent Claim
35 words
The process of claim 12 wherein the flock fibers are composed of material selected from the group consisting of nylon, cotton, rayon, polyesters, wool, mohair, silk, acrylics, modacrylics, natural and synthetic fibers, and blends thereof.
Claim 26
Dependent Claim
24 words
The process of claim 12 wherein the flock adhesive is selected from the group consisting of urethane, vinyl, neoprene, acrylics, vinyl-acrylic, and styrene-butadiene latexes.
Claim 27
Dependent Claim
17 words
The process of claim 12 wherein the substrate backing layer is a woven, knitted, or non-woven fabric.
Claim 28
Dependent Claim
19 words
The process of claim 12 wherein the substrate is selected from the group consisting of natural and synthetic fibers.
Claim 29
Dependent Claim
98 words
A process for producing a breathable laminate comprising: (a) coating a release sheet with an air permeable continuous first layer of a film forming material; (b) distributing flock fibers uniformly onto the first layer; (c) drying the first layer to form a film and securing the flock fibers thereto in a substantially upstanding position; (d) coating only the tips of the flock fibers with a flock adhesive; (e) marrying the flocked fibers to a substrate backing layer such that the coated tips contact the substrate layer; (f) permanently setting the flock adhesive; and (g) removing the release sheet.
Claim 30
Dependent Claim
98 words
A process for producing a breathable laminate comprising: (a) coating a release sheet with an air permeable continuous first layer of a film forming material; (b) distributing flock fibers uniformly onto the first layer; (c) drying the first layer to form a film and securing the flock fibers thereto in a substantially upstanding position; (d) coating only the tips of the flock fibers with a flock adhesive; (e) marrying the flocked fibers to a substrate backing layer such that the coated tips contact the substrate layer; (f) permanently setting the flock adhesive; and (g) removing the release sheet.
Claim 31
Dependent Claim
15 words
The process of claim 26 wherein the air permeable continuous first layer is a foam.
Claim 32
Dependent Claim
12 words
The process of claim 26 wherein the flock adhesive is a foam.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1980-07-04 | 1981-01-03 | 1981-07-05 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1984-07-04 | 1985-01-03 | 1985-07-05 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1988-07-04 | 1989-01-03 | 1989-07-05 | $7700.00 | Window Closed / Lapsed |