Laminated fabric structure containing microspheres and process for making same

• US 4,610,923 A
• Filed: 10/16/1985
• Issued: 09/09/1986
• Est. Priority Date: 10/16/1985
• Status: Expired due to Term

• Current Assignee: Uniroyal Engineered Products LLC (Uniroyal Global Engineered Products, Inc.)
• Original Assignee: Uniroyal Plastics Co., Inc.
• Inventors: Schrock, Fredric L.
• Primary Examiner(s): Van Balen, William J.
• Application Number:
  US06/787,878
• Time in Patent Office: 328 Days
• Field of Search: 156/78, 156/79, 264/257, 428/304.4, 428/313.3, 428/313.5, 428/314.4, 428/314.8, 428/315.5, 428/315.7, 428/315.9, 428/317.1, 428/317.3, 428/317.7
• US Class Current: 428/304.4
• CPC Class Codes: B32B 5/20 foamed in situ
• CPC Class Codes: B32B 5/245 another layer next to it being a foam layer
• CPC Class Codes: B32B 7/12 using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: D06N 3/0027 Rubber or elastomeric fibres
• CPC Class Codes: D06N 3/0029 Stretchable fibres; Stretching of fibres during manufacture
• CPC Class Codes: D06N 3/0056 characterised by the compounding ingredients of the macro-molecular coating D06N3/005 takes precedence
• CPC Class Codes: Y10T 428/249953 Composite having voids in a component [e.g., porous, cellular, etc.]
• CPC Class Codes: Y10T 428/249972 Resin or rubber element
• CPC Class Codes: Y10T 428/249982 With component specified as adhesive or bonding agent

Abstract

This invention relates to the use of microspheres in laminated structures, particularly in foam-backed fabric laminates useful in the manufacture of upholstered items and processes for manufacturing same.

Claims

1. A laminar structure comprising an expandable microspheres-containing elastomeric skin and a stretchable fabric attached thereto.

5. The laminar structure of claim 1 wherein said microspheres are in an expanded state.

2. A laminar structure comprising an elastomeric skin to which is attached a stretchable fabric by means of an adhesive layer;

at least one of the skin and the adhesive layer containing expandable microspheres.

6. The laminar structure of claim 2 wherein said microspheres are in an expanded state.

3. A laminar structure comprising an elastomeric skin to which is attached on one side a stretchable fabric and on the other side an elastomeric top coat, at least one of said skin and said top coat containing expandable microspheres.

7. The laminar structure of claim 3 wherein said microspheres are in an expanded state.

4. A laminar structure comprising an elastomeric skin to which is attached on one side a stretchable fabric by means of an adhesive layer and on the other side an elastomeric top coat, at least one of said skin, adhesive layer and top coat containing expandable microspheres.

8. The laminar structure of claim 4 wherein said microspheres are in an expanded state.

9. A process for the production of laminated fabric structures comprising:

affixing an expandable microsphere-containing elastomeric skin to a stretchable fabric to form a laminate; and

expanding said microspheres in said laminate.

10. A process for the production of laminated fabric structures comprising:

affixing an expandable microsphere-containing elastomeric skin to a stretchable fabric to form a laminate; and

heating said laminate to expand said microspheres.

11. A process for the production of foamed laminated fabric structures comprising:

affixing an expandable microsphere-containing elastomeric skin to a stretchable fabric to form a laminate;

heating said laminate to expand said microspheres;

vacuum forming said microsphere-expanded laminate in a mold;

introducing liquid foamable composition onto said microsphere-expanded laminate in said mold;

causing said composition to foam in a controlled manner; and

removing said foamed laminated fabric structure from said mold.

12. A process for the production of laminated fabric structures comprising:

affixing an elastomeric skin to a stretchable fabric by means of an adhesive layer to form a laminate wherein at least one of said elastomeric skin and said adhesive layer contains expandable microspheres; and

expanding said microspheres in said laminate.

13. A process for the production of foamed laminated fabric structures comprising:

affixing an elastomeric skin to a stretchable fabric by means of an adhesive layer to form a laminate wherein at least one of said elastomeric skin and said adhesive layer contains expandable microspheres;

heating said laminate to expand said microspheres;

vacuum forming said microsphere-expanded laminate in a mold;

introducing liquid foamable composition onto said microsphere-expanded laminate in said mold;

causing said composition to foam in a controlled manner; and

removing said foamed laminated fabric structure from said mold.

14. A process for the production of laminated fabric structures comprising:

affixing an elastomeric top coat to one side of an elastomeric skin;

affixing a stretchable fabric by means of an adhesive layer to the opposite side of said elastomeric skin to form a laminate wherein at least one of said elastomeric topcoat, said elastomeric skin and said adhesive layer contains expandable microspheres; and

expanding said microspheres in said laminate.

15. A process for the production of foamed laminated fabric structures comprising:

affixing an elastomeric top coat to one side of an elastomeric skin;

affixing a stretchable fabric by means of an adhesive layer to the opposite side of said elastomeric skin to form a laminate wherein at least one of said elastomeric topcoat, said elastomeric skin and said adhesive layer contains expandable microspheres;

heating said laminate to expand said microspheres;

vacuum forming said microsphere expanded laminate in a mold;

introducing liquid foamable composition onto said microsphere-expanded laminate in said mold;

causing said composition to foam in a controlled manner; and

removing said foamed laminated fabric structure from said mold.