Moldable construction incorporating bonding interface

• US 20070071941A1
• Filed: 09/11/2006
• Published: 03/29/2007
• Est. Priority Date: 09/27/2005
• Status: Active Grant

• Current Assignee: Milliken & Company
• Original Assignee: Milliken & Company
• Inventors: Callaway, Brian, Eleazer, Howell
• Granted Patent: US 7,294,384 B2
• Time in Patent Office: Days
• US Class Current: 428/92
• CPC Class Codes: B29C 70/24 oriented in at least three directions forming a three dimensional structure
• CPC Class Codes: B32B 2250/05 5 or more layers
• CPC Class Codes: B32B 2250/20 All layers being fibrous or filamentary
• CPC Class Codes: B32B 2262/0253 Polyolefin fibres vinyl or acrylic copolymers B32B2262/0223 or B32B2262/0246
• CPC Class Codes: B32B 2262/0276 Polyester fibres
• CPC Class Codes: B32B 2262/12 Conjugate fibres, e.g. core/sheath or side-by-side
• CPC Class Codes: B32B 2307/31 Heat sealable
• CPC Class Codes: B32B 2307/516 mono-axially
• CPC Class Codes: B32B 27/02 in the form of fibres or filaments not used
• CPC Class Codes: B32B 27/32 comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 3/08 characterised by added members at particular parts layer formed of separate pieces of material which are juxtaposed side-by-side B32B3/14, B32B3/18
• CPC Class Codes: B32B 5/022 Non-woven fabric
• CPC Class Codes: B32B 5/024 Woven fabric
• CPC Class Codes: B32B 5/026 Knitted fabric
• CPC Class Codes: B32B 5/12 characterised by the relative arrangement of fibres or filaments of different layers, e.g. the fibres or filaments being parallel or perpendicular to each other
• CPC Class Codes: B32B 5/26 another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• CPC Class Codes: D03D 15/283 synthetic polymer-based, e.g. polyamide or polyester fibres cellulose-based artificial fibres D03D15/225
• CPC Class Codes: D03D 15/292 Conjugate, i.e. bi- or multicomponent, fibres or filaments
• CPC Class Codes: D03D 15/46 Flat yarns, e.g. tapes or films
• CPC Class Codes: D03D 15/49 textured chenille D03D27/18; curled; crimped
• CPC Class Codes: D03D 15/587 : adhesive; fusible
• CPC Class Codes: D03D 15/593 : Stiff materials, e.g. cane or slat
• CPC Class Codes: D04B 21/165 : with yarns stitched through one or more layers or tows, e.g. stitch-bonded fabrics layered products not united by stitch loops B32B5/22
• CPC Class Codes: D10B 2101/06 : Glass
• CPC Class Codes: D10B 2101/12 : Carbon; Pitch
• CPC Class Codes: D10B 2201/02 : Cotton
• CPC Class Codes: D10B 2321/021 : polyethylene
• CPC Class Codes: D10B 2321/022 : polypropylene
• CPC Class Codes: D10B 2321/06 : polymers of unsaturated alcohols, e.g. polyvinyl alcohol, or of their acetals or ketals
• CPC Class Codes: D10B 2321/10 : polymers of unsaturated nitriles, e.g. polyacrylonitrile, polyvinylidene cyanide
• CPC Class Codes: D10B 2331/021 : aromatic polyamides, e.g. aramides
• CPC Class Codes: D10B 2331/04 : polyesters, e.g. polyethylene terephthalate [PET]
• CPC Class Codes: D10B 2331/10 : polyurethanes
• CPC Class Codes: D10B 2401/041 : thermoplastic; thermosetting
• CPC Class Codes: D10B 2401/062 : stiff, shape retention
• CPC Class Codes: D10B 2401/063 : high strength
• CPC Class Codes: Y10T 428/23914 : Interlaminar
• CPC Class Codes: Y10T 428/23957 : Particular shape or structure of pile
• CPC Class Codes: Y10T 428/23986 : With coating, impregnation, or bond
• CPC Class Codes: Y10T 428/24033 : including stitching and discrete fastener[s], coating or bond
• CPC Class Codes: Y10T 428/24174 : including sheet or component perpendicular to plane of web or sheet
• CPC Class Codes: Y10T 442/3041 : Woven fabric comprises strips or ribbons only
• CPC Class Codes: Y10T 442/3146 : Strand material is composed of two or more polymeric materials in physically distinct relationship [e.g., sheath-core, side-by-side, islands-in-sea, fibrils-in-matrix, etc.] or composed of physical blend of chemically different polymeric materials or a physical blend of a polymeric material and a filler material
• CPC Class Codes: Y10T 442/3472 : Woven fabric including an additional woven fabric layer
• CPC Class Codes: Y10T 442/3602 : Three or more distinct layers
• CPC Class Codes: Y10T 442/643 : Including parallel strand or fiber material within the nonwoven fabric

Abstract

A composite construction comprising a mat structure comprising a plurality of layers, each layer comprising plurality of fibers arranged substantially parallel to one another along a common fiber direction, a multiplicity of embedded fiber elements extending in anchored relation at least partially across the thickness dimension of the mat structure such that at least a portion of the embedded fiber elements project outwardly from the mat structure and the projecting portions define at least a partial surface covering across a first side of the mat structure, and a substrate layer disposed in layered relation to the mat structure in contacting, bonding relation with said first side of the mat structure such that at least a percentage of said portion of embedded fiber elements projecting outwardly from the mat structure is at least partially bonded or embedded into a surface portion of the substrate layer. The composite is adapted for bonding to a substrate layer. At least one interface layer disposed in layered relation to a first side of the mat structure may be included. Additional layers comprising plurality of fibers arranged substantially parallel to one another along a common fiber direction may be utilized.

Claims

1. A composite construction comprising:

a mat structure comprising a plurality of layers, each layer comprising a plurality of monoaxially drawn tape elements, said tape elements comprising a base layer of a strain oriented olefin polymer disposed between covering layers of a heat fusible olefin polymer, wherein said covering layers are characterized by a softening temperature below that of the base layer to permit fusion bonding upon application of heat, and wherein the plurality of layers are fused together;

a multiplicity of embedded fiber elements extending in anchored relation at least partially across the thickness dimension of the mat structure such that at least a portion of the embedded fiber elements project outwardly from the mat structure and the projecting portions define at least a partial surface covering across a first side of the mat structure;

a substrate layer disposed in layered relation to the mat structure in contacting, bonding relation with said first side of the mat structure such that at least a percentage of said portion of embedded fiber elements projecting outwardly from the mat structure is at least partially bonded to a surface portion of the substrate layer.

2. The composite construction of claim 1, wherein the mat structure comprises at least 10 layers.

3. The composite composition of claim 1, wherein each layer of the monoaxially drawn tape elements are woven or knitted.

4. The composite composition of claim 1, wherein the embedded fiber elements comprise non-olefin material.

5. The composite composition of claim 1, further comprising at least one additional layer comprising a plurality of monoaxially drawn tape elements disposed across a second side of the mat structure facing away from the substrate layer such that said at least one additional layer defines an encapsulating barrier layer over the mat structure to substantially cover portions of the embedded fiber elements projecting outwardly from the second side of the mat structure.

6. The composite composition of claim 1, further comprising at least one additional layer comprising a plurality of fibers arranged substantially parallel to one another along a common fiber direction disposed across a second side of the mat structure facing away from the substrate layer such that said at least one additional layer defines an encapsulating barrier layer over the mat structure to substantially cover portions of the embedded fiber elements projecting outwardly from the second side of the mat structure.

7. The composite composition of claim 1, wherein the wherein the multiplicity of embedded fiber elements are stitching yarns extending in stitch-forming anchored relation through one layer of the mat structure.

8. The composite composition of claim 1, wherein said surface portion of the substrate layer comprises an adhesive.

13. The composite composition of claim 1, wherein the wherein the multiplicity of embedded fiber elements are stitching yarns extending in stitch-forming anchored relation through one layer of the mat structure.

9. A composite construction comprising:

a mat structure comprising a plurality of layers, each layer comprising a plurality of monoaxially drawn tape elements, said tape elements comprising a base layer of a strain oriented olefin polymer disposed between covering layers of a heat fusible olefin polymer, wherein said covering layers are characterized by a softening temperature below that of the base layer to permit fusion bonding upon application of heat, and wherein the plurality of layers are fused together;

at least one interface layer disposed in layered relation to a first side of the mat structure;

a multiplicity of embedded fiber elements extending in anchored relation at least partially across the thickness dimension of the mat structure and the interface layer such that at least a portion of the embedded fiber elements project outwardly from the interface layer, the interface layer in combination with said portion of the embedded fiber elements projecting outwardly from the interface layer defining at least a partial covering across the mat structure;

a substrate layer disposed in layered relation to the mat structure in contacting, bonding relation with said interface layer such that at least a percentage of said interface layer is at least partially bonded to a surface portion of the substrate layer.

10. The composite composition of claim 9, further comprising at least one additional layer comprising a plurality of fibers arranged substantially parallel to one another along a common fiber direction disposed across a second side of the mat structure facing away from the substrate layer such that said at least one additional layer defines an encapsulating barrier layer over the mat structure to substantially cover portions of the embedded fiber elements projecting outwardly from the second side of the mat structure.

11. The composite composition of claim 9, wherein the multiplicity of embedded fiber elements are stitching yarns extending in stitch-forming anchored relation at least partially across the mat structure and the interface layer such that at least a portion of the stitching yarns project outwardly from the interface layer, the interface layer in combination with said portion of the embedded fiber elements projecting outwardly from the interface layer defining at least a partial covering across the mat structure.

12. The composite composition of claim 9, wherein the interface layer comprises a non-woven textile.

14. A composite construction comprising:

a mat structure comprising at least 2 layers, at least one layer comprising plurality of fibers arranged substantially parallel to one another along a common fiber direction;

a multiplicity of embedded fiber elements extending in anchored relation at least partially across the thickness dimension of the mat structure such that at least a portion of the embedded fiber elements project outwardly from the mat structure and the projecting portions define at least a partial surface covering across a first side of the mat structure;

a substrate layer disposed in layered relation to the mat structure in contacting, bonding relation with said first side of the mat structure such that at least a percentage of said portion of embedded fiber elements projecting outwardly from the mat structure is at least partially bonded to a surface portion of the substrate layer.

15. The composite construction of claim 14, wherein the mat structure comprises at least 10 layers and the plurality of layers are fused together.

16. The composite composition of claim 14, wherein the plurality of fibers have a tenacity of at least 10 gram/denier.

17. The composite composition of claim 14, wherein the multiplicity of embedded fiber elements are stitching yarns extending in stitch-forming anchored relation at least partially across the mat structure.

18. The composite composition of claim 14, wherein said surface portion of the substrate layer comprises an adhesive.

19. A composite construction comprising:

a mat structure comprising at least 2 layers, at least one layer comprising plurality of fibers arranged substantially parallel to one another along a common fiber direction;

at least one interface layer disposed in layered relation to a first side of the mat structure;

a multiplicity of embedded fiber elements extending in anchored relation at least partially across the thickness dimension of the mat structure and the interface layer such that at least a portion of the embedded fiber elements project outwardly from the interface layer, the interface layer in combination with said portion of the embedded fiber elements projecting outwardly from the interface layer defining at least a partial covering across the mat structure;

a substrate layer disposed in layered relation to the mat structure in contacting, bonding relation with said interface layer such that at least a percentage of said interface layer is at least partially bonded to a surface portion of the substrate layer.

20. The composite composition of claim 19, wherein the multiplicity of embedded fiber elements are stitching yarns extending in stitch-forming anchored relation at least partially across the mat structure and the interface layer such that at least a portion of the stitching yarns project outwardly from the interface layer, the interface layer in combination with said portion of the embedded fiber elements projecting outwardly from the interface layer defining at least a partial covering across the mat structure.

21. The composite composition of claim 19, wherein the interface layer comprises a non-woven textile.