MULTI-LAYER MATERIAL AND METHOD OF APPLICATION

• US 20130186546A1
• Filed: 01/23/2013
• Published: 07/25/2013
• Est. Priority Date: 01/24/2012
• Status: Active Grant

• Current Assignee: Neenah Northeast LLC (Mativ Holdings, Inc.)
• Original Assignee: Arthur Victor Jr. Fleury, Charles E. Snyder, Daniel T. Bunker, Jian Ling Ding
• Inventors: DING, JIAN LING, FLEURY, ARTHUR VICTOR Jr., SNYDER, CHARLES E., HINKLE, JASON CURTIS, BUNKER, DANIEL T.
• Granted Patent: US 11,078,623 B2
• Time in Patent Office: Days
• US Class Current: 156/60
• CPC Class Codes: D06N 3/0011 using non-woven fabrics
• CPC Class Codes: D06N 3/0047 obtained by incorporating air, i.e. froth
• CPC Class Codes: D06N 3/0077 Embossing; Pressing of the surface; Tumbling and crumbling; Cracking; Cooling; Heating, e.g. mirror finish
• CPC Class Codes: D06N 3/14 with polyurethanes
• CPC Class Codes: Y10T 156/10 Methods of surface bonding and/or assembly therefor
• CPC Class Codes: Y10T 428/24504 Component comprises a polymer [e.g., rubber, etc.]
• CPC Class Codes: Y10T 442/649 Plural foamed layers
• CPC Class Codes: Y10T 442/652 Nonwoven fabric is coated, impregnated, or autogenously bonded

Abstract

A multi-layer material suitable for use as a covering for an article includes a polymeric cellular layer and nonwoven backing layer. The multi-layer material having a creasability angle of between about 20 and about 160 degrees.

Claims

1. A multi-layer material suitable for use as a covering for an article, the material comprising:

at least one polymeric cellular layer;

a nonwoven backing layer; and

wherein the material has a creasability angle of between about 20 and 160 degrees.

2. The material of claim 1 further comprising a coating applied to the polymeric cellular layer.

3. The material of claim 2 wherein the coating comprises a latex emulsion.

4. The material of claim 2 wherein the coating is selected from the group consisting of polyurethanes, polyacrylics, polystyrene butadiene, polyethyelene vinyl acetate, vinyl acetate ethylene polymers, polyolefins, or combinations thereof.

5. The material of claim 2 wherein the coating includes a pigment filler, dye, or colorant.

6. The material of claim 1 wherein the nonwoven backing layer comprises a cellulose based substrate.

7. The material of claim 1 wherein the nonwoven backing layer comprises a latex saturated paper.

8. The material of claim 1 wherein the polymeric cellular layer comprises a flexible polymeric matrix having open and closed cells in a density range of about 0.15 g/cc to about 0.8 g/cc.

9. The material of claim 1 wherein the polymeric cellular layer is froth-formed.

10. The material of claim 1 wherein the polymeric cellular layer is selected from the group consisting of polyurethanes, polyacrylics, polystyrene butadiene rubbers, polyethylene vinyl acetates, and blends thereof.

11. The material of claim 1 wherein the polymeric cellular layer includes a pigment filler, dye or colorant.

12. The material of claim 1 in which the at least one polymeric cellular layer is a plurality of polymeric cellular layers.

13. The material of claim 1 wherein the material is embossed to create a texture.

14. A multi-layer material suitable for use as a covering for an article, the material comprising:

a polyurethane cellular layer;

a nonwoven backing layer;

at least one coating on the polyurethane cellular layer; and

wherein the material has a creasability angle of between about 50° and

about 130°

.

15. A method of manufacturing a multi-layer material suitable for use as a covering comprising the steps of:

entraining air or gas into a polymer to create a polymer froth;

applying the polymer froth in a uniform layer to a nonwoven backing layer;

wherein the resulting multi-layer material has a creasability angle of between about 20 and 160 degrees.

16. The method of claim 15 wherein the froth is dried at room temperature to form the multi-layer material.

17. The method of claim 15 wherein the froth is dried in a heated oven between about 200°

to about 400°

F. or in a heated air stream between about 190°

to about 300°

F. to form the multi-layer material.

18. The method of claim 15 further comprising the step of embossing the material.

19. The method of claim 15 further comprising the step of applying a coating to the cellular polymeric layer.

20. The method of claim 15 further comprising the step of printing on the cellular polymeric layer.

21. A method of covering an article with a multi-layer material comprising the steps of:

applying an adhesive to either the article or to a nonwoven backing layer of the material;

placing the material on the article; and

wherein the material includes the nonwoven backing layer and at least one polymeric cellular layer and the material has a creasability angle of between about 20 and 160 degrees.

22. The method of claim 21 wherein the article is selected from the group consisting of boxes, binders, books, journals and diaries.

23. The method of claim 21 wherein the multi-layer material includes the nonwoven backing layer, at least one polymeric cellular layer and at least one coating applied to the polymeric cellular layer and has a creasability angle of between about 20 and 160 degrees.