Multi-layer covering articles

• US 5,843,554 A
• Filed: 02/18/1994
• Issued: 12/01/1998
• Est. Priority Date: 02/18/1994
• Status: Expired due to Fees

• Current Assignee: Katman, Inc.
• Original Assignee: Katman, Inc.
• Inventors: Katz, Donald P.
• Primary Examiner(s): Bell, James J.
• Application Number:
  US08/198,603
• Time in Patent Office: 1,747 Days
• Field of Search: 428/68, 428/70, 428/247, 428/255, 428/284, 428/286, 428/192, 428/340, 428/85, 428/95, 428/74, 442/1, 442/62, 442/64, 442/101, 442/370, 442/398
• US Class Current: 428/68
• CPC Class Codes: B32B 2305/08 Reinforcements
• CPC Class Codes: B32B 2307/558 Impact strength, toughness
• CPC Class Codes: B32B 2307/5825 Tear resistant
• CPC Class Codes: B32B 27/12 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 5/18 characterised by features of a layer of foamed material
• CPC Class Codes: C04B 40/04 Preventing evaporation of the mixing water permanent coverings C04B41/00
• CPC Class Codes: E04G 21/06 Solidifying concrete, e.g. by application of vacuum before hardening devices for solidifying also soil E02D3/02; for road building E01C19/00; for producing shaped articles B28B1/00
• CPC Class Codes: E04H 4/103 with inflatable chambers
• CPC Class Codes: F24S 10/17 using covers or floating solar absorbing elements
• CPC Class Codes: Y02E 10/44 Heat exchange systems
• CPC Class Codes: Y10T 428/23 Sheet including cover or casing
• CPC Class Codes: Y10T 428/232 Encased layer derived from inorganic settable ingredient
• CPC Class Codes: Y10T 428/237 Noninterengaged fibered material encased [e.g., mat, batt, etc.]
• CPC Class Codes: Y10T 428/24777 Edge feature
• CPC Class Codes: Y10T 442/10 Scrim [e.g., open net or mesh, gauze, loose or open weave or knit, etc.]
• CPC Class Codes: Y10T 442/2025 Coating produced by extrusion
• CPC Class Codes: Y10T 442/2041 Two or more non-extruded coatings or impregnations
• CPC Class Codes: Y10T 442/2344 Coating or impregnation is anti-slip or friction-increasing other than specified as an abrasive
• CPC Class Codes: Y10T 442/647 Including a foamed layer or component
• CPC Class Codes: Y10T 442/678 Olefin polymer or copolymer sheet or film [e.g., polypropylene, polyethylene, ethylene-butylene copolymer, etc.]

Abstract

Multi-layer covering articles having a base layer adapted to yieldably conform to a surface to be covered and having properties appropriate for a particular application in which the article is to be used, and a thermoplastic surface layer bonded to a surface of the base layer and incorporating a reinforcing material to provide strength and tear resistance for the covering article. The reinforcing material permits the surface layer to function as the strength-providing member of the article, permitting the base layer to be designed solely in accordance with the requirements of a particular application without regard to its strength. Preferred embodiments of the invention include a concrete curing blanket in which the base layer includes a porous, non-woven synthetic fabric having optimum liquid retention and spreading properties and which is very thin and light in weight, and a solar heating swimming pool cover in which the base layer is formed of a plastic bubble sheet and the surface layer includes a black or other heat-absorbing color layer for heating water in the pool by conduction of solar energy therethrough. The reinforcing layer allows for lightweighting of the total product with the ability, if desired, to add dark and light (reflective) sides or the traditional translucent look in lightweight form.

Claims

1. A multi-layer covering article for covering a surface comprising:

a base layer which is yieldably conformable to a surface to be covered by the covering article and having desired properties for a particular application; and

a surface layer covering a surface of said base layer, said surface layer comprising a thermoplastic layer bonded to said base layer and incorporating a reinforcing material to provide strength and tear resistance for the covering article, said reinforcing material comprising a reinforcing scrim.

3. The covering article of claim 1 wherein said covering layer comprises a concrete curing blanket, and wherein said base layer comprises a base layer of a porous non-woven, synthetic fabric having desired liquid retention and spreading properties to maintain the surface of concrete in a wetted condition.

5. The covering article of claim 1 wherein said covering article comprises a swimming pool cover.

8. The covering article of claim 1 wherein said covering article comprises a floor covering.

9. The covering article of claim 8 and further including a barrier layer for liquid retention.

31. The multi-layer covering article of claim 1 wherein at least one of said surface layer and said base layer of said article includes one or more coextruded thermoplastic films which comprise a plurality of coextruded layers, said plurality of coextruded layers including one or more barrier layers for functioning as barriers for specific materials.

32. The multi-layer covering article of claim 31 wherein said one or more barrier layers includes an oxygen barrier layer.

35. The multi-layer covering article of claim 31 wherein both said surface layer and said base layer of said article includes said one or more coextruded thermoplastic films.

37. The covering article of claim 5 wherein at least one of said base layer and said surface layer includes one or more coextruded thermoplastic films which comprise a plurality of coextruded layers.

38. The covering article of claim 37 wherein said one or more coextruded films includes a clear film.

39. The covering article of claim 37 wherein said one or more coextruded films includes a black or other absorbent color layer.

40. The covering article of claim 37 wherein said one or more coextruded films includes a white or other reflective color layer.

41. The covering article of claim 37 wherein said one or more coextruded films includes a black or other absorbent color layer facing toward one side of said article and a white or other reflective color layer facing toward a side of said article opposite said one side.

42. The covering article of claim 5 wherein said surface layer includes a white or other reflective color layer, and wherein said cover is positionable over a swimming pool with the base layer in contact with a surface of the pool and the white or other reflective color layer of said surface layer facing upwardly for reflecting solar energy away from said covering article and said swimming pool for maintaining said pool at a desired temperature.

43. The covering article of claim 5 wherein one of said base layer and said surface layer comprises a black or other absorbent color layer and the other of said base layer and said surface layer comprises a white or other reflective color layer, and wherein said swimming pool cover is positionable over a swimming pool either with the black or other absorbent color layer thereof facing upwardly for absorbing solar energy for heating the swimming pool by conduction, or with the white or other reflective color layer thereof facing upwardly for reflecting solar energy away from the covering article and said pool for maintaining said swimming pool at a desired temperature.

44. The covering article of claim 5 wherein said base layer includes a coextruded formed layer.

48. The covering article of claim 1 wherein said base layer includes a foamed layer.

49. The covering article of claim 1 wherein said base layer includes a bubble plastic sheet.

2. A multi-layer covering article for covering a surface comprising:

a base layer which is yieldably conformable to a surface to be covered by the covering article and having desired properties for a particular application; and

a surface layer covering a surface of said base layer, said surface layer comprising a thermoplastic layer bonded to said base layer and incorporating a reinforcing material to provide strength and tear resistance for the covering article, wherein said surface layer includes a portion which extends beyond at least one edge of said base layer to define a flap means for overlapping and attachment to a surface layer of an adjacent covering article without overlapping of the base layers of the covering article and the adjacent covering article.

4. A multi-layer covering article for covering a surface, said multi-layer covering article comprising a concrete curing blanket and including:

a base layer which is yieldably conformable to a surface to be covered by the covering article and having desired properties for a particular application, said base layer comprising a base layer of a porous non-woven, synthetic fabric having desired liquid retention and spreading properties to maintain the surface of concrete in a wetted condition, said fabric having an absorbent material added thereto to increase absorbency; and

a surface layer covering a surface of said base layer, said surface layer comprising a thermoplastic layer bonded to said base layer and incorporating a reinforcing material to provide strength and tear resistance for the covering article.

6. A multi-layer covering article for covering a surface, said multi-layer covering article comprising a swimming pool cover and including:

a base layer which is yieldably conformable to a surface to be covered by the covering article and having desired properties for a particular application, said base layer comprising a bubble plastic sheet; and

a surface layer covering a surface of said base layer, said surface layer comprising a thermoplastic layer bonded to said base layer and incorporating a reinforcing material to provide strength and tear resistance for the covering article.

7. A multi-layer covering article for covering a surface, said multi-layer covering article comprising a swimming pool cover and including:

a base layer which is yieldably conformable to a surface to be covered by the covering article and having desired properties for a particular application; and

a surface layer covering a surface of said base layer, said surface layer comprising a thermoplastic layer bonded to said base layer and incorporating a reinforcing material to provide strength and tear resistance for the covering article, wherein said surface layer includes a portion which extends beyond at least one edge of said base layer to define a flap means for overlapping and attachment to a surface layer of an adjacent cover without overlapping of the base layers of the cover and adjacent cover.

10. A multi-layer covering article for covering a surface, said multi-layer covering article comprising a floor covering and including:

a base layer which is yieldably conformable to a surface to be covered by the covering article and having desired properties for a particular application;

a surface layer covering a surface of said base layer, said surface layer comprising a thermoplastic layer bonded to said base layer and incorporating a reinforcing material to provide strength and tear resistance for the covering article; and

an anti-skid layer for preventing said article from slipping on a surface covered by said article.

11. A multi-layer covering article for covering a surface, said multi-layer covering article comprising a floor covering and including:

a base layer which is yieldably conformable to a surface to be covered by the covering article and having desired properties for a particular application; and

a surface layer covering a surface of said base layer, said surface layer comprising a thermoplastic layer bonded to said base layer and incorporating a reinforcing material to provide strength and tear resistance for the covering article, wherein said surface layer includes a portion which extends beyond at least one edge of said base layer to define a flap means for overlapping and attachment to a surface layer of an adjacent floor covering without overlapping of the base layers of the floor covering and adjacent floor covering.

12. A concrete curing blanket comprising:

a base layer of a porous, non-woven, synthetic fabric which is yieldably conformable to a concrete surface to be covered by the blanket and having desired liquid retention and spreading properties to maintain the surface of the concrete in a wetted condition; and

a surface layer covering a surface of said base layer, said surface layer comprising a thermoplastic layer bonded to said base layer and incorporating a reinforcing material to provide strength and tear resistance for the blanket, said reinforcing material comprising a reinforcing scrim.

13. The concrete curing blanket of claim 12 wherein said reinforcing scrim comprises an extruded scrim, and wherein said cover layer is extrusion coated onto said base layer.

14. The concrete curing blanket of claim 12 wherein said base layer comprises a non-woven synthetic fabric manufactured from polyester or a polyolefin including low density polyethylene, linear low density polyethylene, high density polyethylene or polypropylene.

15. The concrete curing blanket of claim 14 wherein said base layer has a weight of less than four ounces per square yard.

16. A concrete curing blanket comprising:

a base layer of a porous, non-woven, synthetic fabric which is yieldably conformable to a concrete surface to be covered by the blanket and having desired liquid retention and spreading properties to maintain the surface of the concrete in a wetted condition; and

a surface layer covering a surface of said base layer, said surface layer comprising a thermoplastic layer bonded to said base layer and incorporating a reinforcing material to provide strength and tear resistance for the blanket, wherein said surface layer includes a portion which extends beyond at least one edge of said base layer to define a flap means for overlapping and attachment to a surface layer of an adjacent blanket without overlapping of the base layers of the blanket and adjacent blanket.

17. A swimming pool cover comprising:

a base layer which is yieldably conformable to a surface of a swimming pool to be covered by the cover and having desired heat-absorbing and heat retention properties, said base layer comprising a bubble plastic sheet; and

a surface layer covering a surface of said base layer, said surface layer comprising a thermoplastic layer bonded to said base layer and incorporating a reinforcing material to provide strength and tear-resistance for the cover.

18. The swimming pool cover of claim 17 wherein said base layer includes a clear bubble plastic sheet and said surface layer includes a thermoplastic layer of black or other absorbent color, and wherein said cover is positionable on the surface of a swimming pool with the bubble plastic sheet facing upwardly and the surface layer in contact with the surface of the pool with the black or other absorbent color layer thereof facing upwardly whereby solar energy passes through said bubble plastic sheet and is absorbed by said black or other absorbent color layer of said surface layer for heating the swimming pool by conduction.

19. The swimming pool cover of claim 18 wherein said surface layer comprises a multiple layer surface layer including said black or other absorbent color layer and a white or other reflective color layer, and wherein said cover is positionable over said swimming pool with the plastic bubble sheet in contact with the surface of the pool and the white or other reflective color layer of said surface layer facing upwardly for reflecting solar energy away from said cover and said swimming pool for maintaining said swimming pool at a desired temperature.

27. The swimming pool cover of claim 17 wherein said bubble plastic sheet comprises a clear bubble plastic sheet.

28. The swimming pool cover of claim 17 wherein said bubble plastic sheet comprises a translucent bubble plastic sheet.

29. The swimming pool cover of claim 17 wherein said bubble plastic sheet comprises a black or other absorbent color bubble plastic sheet.

30. The swimming pool cover of claim 17 wherein said bubble plastic sheet comprises a white or other reflective color bubble plastic sheet.

33. The swimming pool cover of claim 17 wherein at least one of said surface layer and said base layer of said cover includes one or more coextruded thermoplastic films which comprise a plurality of coextruded layers, said plurality of coextruded layers including one or more barrier layers for functioning as barriers for specific materials.

34. The swimming pool cover of claim 33 wherein said one or more barrier layers includes an oxygen barrier layer.

36. The swimming pool cover of claim 33 wherein both said surface layer and said base layer of said cover includes said one or more coextruded thermoplastic films.

45. The swimming pool cover of claim 17 wherein said surface layer includes a white or other reflective color layer, and wherein said cover is positionable over said swimming pool with the base layer in contact with the surface of said pool and the white or other reflective color layer of said surface layer facing upwardly for reflecting solar energy away from said cover and said swimming pool for maintaining said swimming pool at a desired temperature.

20. A swimming pool cover comprising:

a base layer which is yieldably conformable to a surface of a swimming pool to be covered by the cover and having desired heat-absorbing and heat retention properties; and

a surface layer covering a surface of said base layer, said surface layer comprising a thermoplastic layer bonded to said base layer,

said surface layer comprising a multiple layer surface layer including a black or other absorbent color layer and a white or other reflective color layer, and wherein said cover is positionable on the surface of a swimming pool with the base layer facing upwardly and the surface layer in contact with the surface of the pool with the black or other absorbent color layer thereof facing upwardly whereby solar energy passes through said base layer and is absorbed by said black or other absorbent color layer of said surface layer for heating the swimming pool by conduction, and wherein said cover is positionable over said swimming pool with the base layer in contact with the surface of the pool and the white or other reflective color layer of said surface layer facing upwardly for reflecting solar energy away from said cover and said swimming pool for maintaining said swimming pool at a desire temperature.

21. The swimming pool cover of claim 20 wherein said surface layer incorporates a reinforcing material to provide strength and tear-resistance for the cover.

22. The swimming pool cover of claim 20 wherein said surface layer further includes one or more barrier layers for functioning as an oxygen barrier.

23. The swimming pool cover of claim 20 wherein said base layer comprises a clear bubble plastic sheet.

46. The swimming pool cover of claim 20 wherein said base layer includes a coextruded foamed layer.

47. The swimming pool cover of claim 46 wherein said coextruded foamed layer includes a polyethylene or polypropylene foamed layer.

24. A covering article comprising:

a base layer which is yieldably conformable to a surface to be covered by the covering article, said base layer including cushioning and liquid absorbent properties;

a surface layer covering a surface of said base layer, said surface layer comprising a thermoplastic barrier layer bonded to said base layer for containing liquid absorbed by said base layer and for serving as a strength-provided layer for said article; and

an anti-skid layer for preventing said covering article from sliding on said surface to be covered.

25. The covering article of claim 24 wherein said base layer comprises needle-punch, staple fiber polypropylene.

26. The covering article of claim 24 wherein said covering article comprises a floor covering.