Abstract:
The present invention is directed to multiple layer composites ( 10 ) suitable for use as wall and floor coverings, among other uses, that provide a strong durable structure and a soft textile or fabric face. The composite includes a face layer ( 12 ) bonded to an adhesive layer ( 22 ) such that the adhesive layer ( 22 ) penetrates into the face layer ( 12 ). The face layer ( 12 ) can have legs ( 19, 34 ) extending there from, and such legs ( 19, 34 ) are anchored by the adhesive layer to provide stronger attachment between the adhesive layer and the face layer. A backing layer ( 26 ) may also be provided in contact with the adhesive layer ( 22 ) such that the adhesive layer also embeds into the backing layer ( 26 ), and the legs ( 19, 34 ) extending from the face layer may penetrate into the backing layer.

Description:
TECHNICAL AREA  
       [0001]     The present invention relates to fabric-faced laminates for use as floor coverings.  
       BACKGROUND  
       [0002]     Floor coverings are generally selected based upon a combination of factors including aesthetic features such as the look and feel of the floor covering and functional qualities such as retention of surface appearance, stain resistance, moisture resistance, ease of cleaning, and resistance to collection of dirt. For example, floor covering installations in high traffic areas or areas prone to moisture and stains such as kitchens generally use solid surface cover materials for the flooring or interior wall coverings such as wood, metal, marble, ceramic tile, vinyl or rubber. These products retain their surface appearance after heavy use and they are simple to keep clean. They also are resistant to stains and moisture, and less prone to harboring bacterial growth. However, these products lack the textile hand, softness or sound dampening qualities of textile products.  
         [0003]     In installations where aesthetic qualities such as texture and softness are desired, products such as tufted, knit, knotted or woven structures, including velour or velvet are used. These products provide softness and cushion, a soft textile hand and a degree of abrasion and wear resistance. Compared to rigid solid surfaced products, however, these floor coverings are less durable, tend to lose their texture with heavy use, because the pile tends to mat or to be crushed with heavy traffic, tend to collect dust and dirt, provide spaces that allow the growth of bacteria, and are difficult to clean and sanitize.  
         [0004]     Attempts have been made to create products having both the desired functional qualities of solid surface materials and the aesthetic qualities of textile or fabric materials. For example, hybrid structures with partially fibrous and partially solid faces are disclosed in U.S. Pat. No. 3,943,018. These hybrid structures, however, merely reduce but do not eliminate the limitations of regular tufted, velour, or flocked textile surfaces.  
         [0005]     Other attempts provide flat or profiled, e.g., sculpted, surfaces containing fibrous layers impregnated with a plastic matrix. Examples of fibrous layers impregnated with a plastic matrix are disclosed in U.S. Pat. Nos. 4,035,215, 4,098,629, and 6,063,473. These floor coverings generally have surfaces with a semi-fibrous feel, and the spaces between the fibers may be sufficiently sealed to prevent bacterial penetration and dirt collection. In addition, these floor coverings also provide a higher matting resistance than regular upright-oriented fiber structures. However, these floor covering products largely have a stiff leathery appearance rather than a soft textile feel, and the cost of preparing dimensionally-stable dense fibrous products, combined with the cost of impregnating and heat setting can be very high.  
         [0006]     U.S. Pat. No. 3,860,469 discloses another technique to produce inexpensive, dirt and bacterial growth resistant, and abrasion resistant surface covering materials with a textile fiber appearance in which flat or textured film-like skins are placed on top of a pile-like surface. The resultant floor covering products combine the qualities of carpet with the solidity of vinyl or rubber, but lack the textile quality and aesthetics of carpets.  
         [0007]     Other attempts assemble a basically flat textile fabric over a sublayer of adhesive backed with various layers of sub-surface reinforcement. For example, International Patent Publication No. WO 99/19557 discloses a woven face fabric backed by reinforcing layers, and U.S. Pat. No. 5,965,232 discloses a decorative fabric attached to dimensionally-stabilizing or cushioning layers. The fabric is further surface-stabilized. Laminates having a flat fabric face, however, tend to delaminate or fray at the edges unless the fabric is thoroughly impregnated with adhesives. Unfortunately, impregnation with adhesives adversely affects the textile feel and cushioning quality of the laminate.  
         [0008]     Because of these shortcomings, the need remains to provide a surface covering material that combines the desirable properties of both solid surface coverings and textile-type coverings into a single product. Suitable surface coverings would have at least some of the desired properties of surface stability, edge fray resistance, thermal stability, structural stability, dimensional stability, dirt resistance, bacteria resistance, soft textile hand, cushioning, and appearance extending over a full spectrum of tufted, knit, non-woven, woven, velour and velvet products.  
       SUMMARY OF THE INVENTION  
       [0009]     Composite materials in accordance with the present invention utilize a fibrous face layer combined with an adhesive layer to form a multi-layer structure. In order to provide the desired level of surface stability, the surface fibers of the fibrous face layer form loops, and the loops descend into the adhesive layer and are anchored in the adhesive layer. The loops are densely spaced and shallow. Although any portion of the fibers or legs of the looped fibers in the face layer can be dispersed in the adhesive, a significant amount or substantially all of the descending fibers are dispersed in the adhesive layer, which is in contact with the face layer. A characteristic of this invention is that short and densely spaced fiber loops embedded in adhesive provide improved surface stability and retention of appearance under repeated loading. Another characteristic is the resistance to cut-edge fraying.  
         [0010]     In order to maintain the desired aesthetic qualities of the composite material while achieving increased surface stability, the amount of penetration of the adhesive into the face layer is controlled. The adhesive layer is not allowed to penetrate into the top portion of the face layer. Therefore, the top of the face layer maintains its textile feel.  
         [0011]     Various types of fibrous face layer constructions can be used depending upon the aesthetics desired and a balance of cost vs. performance. Regardless of the type of fibrous layer used, all of the embodiments and arrangements illustrated herein have a relatively fine and dense surface texture and they can also be embossed to produce three-dimensional textured products. In addition, a three layer composite structure can be provided wherein a backing layer is also bonded or laminated to the adhesive layer such that the adhesive layer is disposed between the face layer and the backing layer. Added structural rigidity is provided by having the adhesive layer penetrate into the backing layer as well.  
         [0012]     To prepare a composite material in accordance with the present invention, a fibrous face layer is arranged to have a relatively smooth top surface with a high density of fiber loop legs extending down through the thickness of the face layer to the bottom surface. An adhesive layer is brought into direct contact with the bottom surface of the face layer and embedded into the face layer to cause the adhesive to penetrate partially into the thickness of the face layer. In order to embed the adhesive layer in the face layer, pressure and heat can be applied. For a three layer laminate, the backing layer can be brought into direct contact with the adhesive layer before the adhesive layer is embedded into the face layer, allowing the adhesive layer to simultaneously penetrate into the backing layer. The adhesive layer may be pre-integrated onto the face layer or onto the backing layer before lamination. The adhesive layer may also contain non-adhesive reinforcing or blended components. The backing layer may also contain adhesive components, which may replace the need for a separate adhesive layer, if the adhesive is present in sufficient quantity to anchor and envelope the legs of the surface fiber loops descending into it.  
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0013]      FIG. 1  is a schematic representation of a three layer embodiment of the composite material in accordance with the present invention;  
         [0014]      FIG. 2  is schematic representation of another three layer embodiment of the composite material;  
         [0015]      FIG. 3  is a schematic representation of another three layer embodiment of the composite material;  
         [0016]      FIG. 4  is a schematic representation of another three layer embodiment of the composite material;  
         [0017]      FIG. 5  is a schematic representation of a non-woven fabric layer;  
         [0018]      FIG. 6  is schematic representation of a needle punched non-woven fabric layer;  
         [0019]      FIG. 7  is a schematic representation of a needle punched non-woven face layer embodiment of the present invention before lamination;  
         [0020]      FIG. 8  is schematic representation of a needle punched non-woven face layer embodiment of the present invention after lamination;  
         [0021]      FIG. 9  is a schematic representation of a non-woven fabric layer in contact with an adhesive layer;  
         [0022]      FIG. 10  is a schematic representation of a non-woven fabric layer needle punched through an adhesive layer;  
         [0023]      FIG. 11  is a schematic representation of a non-woven fabric layer in combination with an adhesive layer and a backing layer;  
         [0024]      FIG. 12  is a schematic representation of a non-woven fabric layer needle punched through an adhesive layer and a backing layer before lamination;  
         [0025]      FIG. 13  is a schematic representation of a non-woven fabric layer needle punched through an adhesive layer and a backing layer after lamination;  
         [0026]      FIG. 14  is a schematic representation of a stitchbonded fabric layer before gathering;  
         [0027]      FIG. 15  is a schematic representation of a stichbonded fabric layer after gathering;  
         [0028]      FIG. 16  is a schematic representation of a gathered stitchbonded fabric layer in combination with an adhesive layer and a backing layer before lamination;  
         [0029]      FIG. 17  is a schematic representation of a gathered stitchbonded fabric layer in combination with an adhesive layer and a backing layer after lamination;  
         [0030]      FIG. 18  is a schematic representation of a stichbonded fabric layer having an adhesive layer before gathering;  
         [0031]      FIG. 19  is a schematic representation of a stichbonded fabric layer having an adhesive layer after gathering;  
         [0032]      FIG. 20  is a schematic representation of a pattern bonded fabric layer before bonding and gathering;  
         [0033]      FIG. 21  is a schematic representation of a pattern bonded fabric layer after bonding and before gathering;  
         [0034]      FIG. 22  is a schematic representation of a gathered pattern bonded fabric layer in combination with an adhesive layer and a backing layer before lamination;  
         [0035]      FIG. 23  is a schematic representation of a gathered pattern bonded fabric layer in combination with an adhesive layer and a backing layer after lamination;  
         [0036]      FIG. 24  is a schematic representation of a pattern bonded fabric layer having an adhesive layer before bonding and gathering;  
         [0037]      FIG. 25  is a schematic representation of a pattern bonded fabric layer having an adhesive layer after bonding and before gathering;  
         [0038]      FIG. 26  is a schematic representation of a bonded and gathered pattern bonded fabric layer having an adhesive layer;  
         [0039]      FIG. 27  is a schematic representation of a reversed pile knit fabric for use in the present invention;  
         [0040]      FIG. 28  is a schematic representation of a reversed pile knit fabric having cut and raised free fiber ends for use in the present invention;  
         [0041]      FIG. 29  is a schematic representation of a woven fabric for use in the present invention;  
         [0042]      FIG. 30  is a schematic representation of a woven fabric having cut and raised free fiber ends for use in the present invention;  
         [0043]      FIG. 31  is a schematic representation of an embodiment of an apparatus for stabilizing a woven or knit face layer during cutting and raising of fibers;  
         [0044]      FIG. 32  is a schematic representation of another embodiment of an apparatus for stabilizing a woven or knit face layer during cutting and raising of fibers; and  
         [0045]      FIG. 33  is a schematic representation of a stichbonded fabric layer containing an adhesive layer.  
     
    
     DETAILED DESCRIPTION  
       [0046]     Referring initially to  FIGS. 1-4 , a fabric-faced composite material  10  in accordance with the present invention includes a face layer  12  containing a plurality of fibers. Suitable fabrics for face layer  12  include, but are not limited to, woven, non-woven, knit, stitchbonded or gathered structures. The face layer  12  includes top side or surface  16  and bottom side or surface  18  opposite top surface  16 , defining thickness  20  of face layer  12  between them. Top surface  16  is the surface or face of composite material  10  that is exposed when the laminate  10  is installed, for example on a substrate in a flooring application.  
         [0047]     Composite material  10  also includes adhesive layer  22  disposed adjacent face layer  12  in direct contact with bottom surface  18 . Preferably, adhesive layer  22  is continuous or is composed of a single, smooth uninterrupted surface. Alternatively, adhesive layer  22  has a substantially constant thickness. Adhesive layer  22  can contain thermoplastic or thermosetting adhesives. Suitable materials for adhesive layer  22  include polyethylene, polypropylene, copolyester, copolyamide and combinations thereof. Suitable basis weights for adhesive layer  22  range from about 3 oz/yd 2  to about 14 oz/yd 2 , preferably about 4 oz/yd 2  to about 10 oz/yd 2 .  
         [0048]     Adhesive layer  22  penetrates into face layer  12  distance  24 , which is sufficient to anchor face layer  12  and adhesive layer  22  together. In one embodiment, distance  24  ranges from about ¼ to about ¾ of thickness  20  of face layer  12 . Preferably, adhesive layer  22  does not penetrate completely through to top surface  16  of face layer  12  in order to preserve the soft, textile feel of composite material  10 . The depth of penetration of adhesive layer  22  into face layer  12  can be controlled by varying the construction of face layer  12 , the construction of adhesive layer  22  or the process conditions used to embed adhesive layer  22  into face layer  12 . In one embodiment, the viscosity of adhesive layer  22  is adjusted to limit the depth of penetration to within the lower ¾ of face layer  12  so that at least the upper ¼ of face layer  12  is free of adhesive. The average height  60  of the face layer above the average level of adhesive penetration varies between about 0.5 mm and about 2.0 mm, and the basis weight is in the range of about 100 grams/m 2  to about 500 grams/m 2 .  
         [0049]     In general, the penetration of adhesive layer  22  into face layer  12  increases the amount or surface area of the adhesive layer that is in contact with the structure or fibers of the face layer  12 . Increasing the surface area contact between adhesive layer  22  and face layer  12  increases the strength of the bond between the two layers and the overall rigidity and strength of the resulting two layer laminate. Overall, this arrangement yields a composite material  10  with improved structural strength and rigidity and a pleasurable soft texture.  
         [0050]     Although composite materials  10  in accordance with the present invention can contain just two layers, face layer  12  and adhesive layer  22 , additional layers may also be included. In three layer arrangements as illustrated in  FIGS. 1-4 , composite material  10  also includes backing layer  26  in direct contact with adhesive layer  22 . Backing layer  26  is disposed such that adhesive layer  22  is disposed between backing layer  26  and face layer  12 . In order to provide increased structural rigidity, adhesive layer  22  also preferably penetrates or extends into backing layer  26 . Additional layers such as a gas permeable layer, bactericide layer or the like can also be added. As used herein, backing layer includes any layer, composite or laminate being attached to composite  10 . Composite  10  can also be embossed and simultaneously bonded and/or laminated to any backing layer.  
         [0051]     In either the two layer or three layer embodiments of the current invention, the layers are laminated together by applying pressure and heat, preferably from top surface  16 , to cure or melt adhesive layer  22  and to control the depth of adhesive penetration. For thermosetting adhesives, adhesive layer  22  can be applied to bottom surface  18  of face layer  12  or to the top of backing layer  26  and the resultant structure can be cured under pressure with a hot tool at a temperature that cures adhesive layer  22  but leaves the fibers in face layer  12  and backing layer  26  intact. For thermoplastic adhesives, adhesive layer  22  is preferably pre-attached to bottom surface  18  of face layer  12  or the top face of backing layer  26  and preheated or pre-melted in-situ, for example by applying radiant heat, before all of the layers are laminated together under pressure. In one embodiment, adhesive layer  22  is preheated before applying pressure to adhesive layer  22 , face layer  12  or backing layer  26 .  
         [0052]     A wide variety of materials can be used as backing layer  26  depending upon the desired thickness, strength and flexibility of three layer composite material  10 . In one embodiment, backing layer  26  is a pre-needled layer of higher-denier fibers of up to about 20 denier per filament or fiber and weighing at least about 10 oz/yd 2 . In another embodiment, backing layer  26  is a needled felt of reclaimed carpet fibers. In yet another embodiment, backing layer  26  is a used tufted carpet.  
         [0053]     Although the fibers in face layer  12  at bottom surface  18  are spaced from backing layer  26 , these fibers can alternatively extend completely through adhesive layer  22  and be in contact with backing layer  26 . In addition, these fibers can extend completely through the adhesive layer  22  and into the backing layer  26  and even through the entire thickness of backing layer  26 . These arrangements can be achieved by controlling the composition of adhesive layer  22  and the process used to laminate the three layers together as discussed below. In addition, separate processes, for example needle punching, can be used to interlock the fibers of face layer  12  into adhesive layer  22  and backing layer  26 .  
         [0054]     In general, the bottom surface  18  of fibrous face layer  12  includes a plurality of legs  19  dependent there from. Legs  19  are anchored into adhesive layer  22  in composite  10  and in some embodiments extend into backing layer  26 . Legs  19  include structures of face layer  12  such as free fiber ends of needle punched or spunlaced/hydraulically needled loops,  FIG. 1 , undulating gathered loops of stitchbonded or pattern bonded fabrics,  FIG. 2 , pile loops of knit fabrics,  FIG. 3 , and cut and raised free fiber ends of knit and woven fabrics,  FIG. 4 . The term “legs” or “legs formed from loops” as used herein includes all of these structures or portions thereof, and also includes any remaining fiber portions of the loops that have been cut to form piles. Processes such as laminating using pressure and heat and needle punching are used to anchor legs  19  into adhesive layer  22 .  
         [0055]     In one embodiment in accordance with the present invention as shown in  FIGS. 5-8 , composite material  10  includes needled, non-woven face layer  12  containing a plurality of fibers  14 . In one embodiment, non-woven face layer  12  contains a web of staple fibers. Suitable staple fibers range from about 0.5 denier to about 5 denier per filament or fiber and have a length ranging from about 0.5 inches to about 3 inches, forming a non-woven web having a weight ranging from about 3 oz/yd 2  to about 14 oz/yd 2 .  
         [0056]     Although fibers  14  are initially arranged in a generally planar pattern in face layer  12  as illustrated in  FIG. 5 , a portion of fibers  14  are needle punched or hydraulically needled (spunlaced) toward bottom surface  18  as illustrated in  FIG. 6 . When mechanical needle punching is used, the needling density is at least over 500 penetrations per inch (ppi) and preferably over 1,000 ppi. The web of fibers  14  is needled from top surface  16  with a relatively large number of needle penetrations per unit area. Generally, the needle punch density is from about 250 needles/in 2  to about 2000 needles/in 2 . In one embodiment, web  14  has a needle punch density of at least about 250 needles/in 2 . Alternatively, the needle punch density is at least about 500 needles/in 2 . Preferably, the needle punch density is at least 1000 needles/in 2 .  
         [0057]     The product of  FIG. 5  can also be formed using hydraulic needling (spunlacing). Preferably, the needled web consists of shorter fibers, up to about 2 inches long, preferably less than about 1 inch and more preferably shorter fibers, including pulps. Also, preferably the needling jets are relatively not dense, e.g., less than 50 penetrations/inch. The needling is performed substantially or totally from the top, and the needling energy is relatively high, e.g., at least 20 HP·HR/lb.  
         [0058]     In this embodiment, face layer  12  is densified and acquires a relatively smooth top surface or upper face  16  containing a plurality of loops  32  facing downward. Each loop  32  contains free fiber ends or legs  34  that descend through face layer  12  and terminate at bottom surface  18 . In order to form a three layer configuration of this embodiment, adhesive layer  22  is placed in direct contact with bottom side  18  and backing layer  26  such that adhesive layer  22  is disposed between face layer  12  and backing layer  26  as is shown in  FIG. 7 . After activation of adhesive layer  22  as shown in  FIG. 8 , adhesive layer  22  penetrates partially into face layer  12  and backing layer  26 , laminating all three layers together. Needled fibers  14  are anchored in adhesive layer  22  at legs  34  of loops  32 . The upper strata or layers of face layer  12  remain free of adhesive from adhesive layer  22 .  
         [0059]     Preferably, in this embodiment, the selected non-woven face layer  12 ,  FIG. 5 , is needle punched or spunlaced (hydraulically needled) to produce a plurality of free fiber ends  34  at bottom surface  18 ,  FIG. 6 . Continuous adhesive layer  22  is then placed in direct contact with bottom surface  18 ,  FIG. 7 , and adhesive layer  22  is embedded into face layer  12  a sufficient distance to anchor face layer  12  in adhesive layer  22 . In order to embed adhesive layer  22  into face layer  12 , adhesive layer  22  is heat activated. Pressure may also be applied to top surface  16  of face layer  12 . A variety of methods can be used to apply heat and pressure to top surface  16  such as contacting top surface  16  with one or more heated pressure plates (not shown). Adhesive layer  22  may also be preheated as for example with radiant heat before placing face layer  12  upon it.  
         [0060]     Referring to  FIGS. 9 and 10 , face layer  12  is brought into direct contact with adhesive layer  22  before face layer  12  is needle punched,  FIG. 9 . Then, face layer  12  is needle punched so that free fiber ends  34  penetrate into and in some cases completely through adhesive layer  22 . Spunlacing or hydraulic needling is not applicable with the embodiment shown in  FIGS. 9 and 10 . In this embodiment, adhesive layer  22  may constitute a low-melt thermoplastic sheet or layer, e.g. polyethylene, polypropylene, low-melt copolyester or copolyamide. This sheet or layer can be in the form of a film or fabric, for example a non-woven fabric, or a layer of low-melt fibers. After the fibers are needle punched into adhesive layer  22 , adhesive layer  22  is heat activated and laminated to face layer  12  using pressure as described above.  
         [0061]     Referring to  FIGS. 11-13 , in addition to bringing adhesive layer  22  into contact with face layer  12  prior to needle punching, backing layer  26  can also be brought into contact with adhesive layer  22  before needle punching. In this three layer embodiment, backing layer  26  is placed in direct contact with adhesive layer  22  such that adhesive layer  22  is disposed between backing layer  26  and face layer  12  ( FIG. 11 ). Then, face layer  12  is needle punched resulting in fiber ends  34  that extend completely through adhesive layer  22  and into backing layer  26  ( FIG. 12 ). The composite material  10  is then finished by heat activating adhesive layer  22  in-situ with or without substantial applied pressure ( FIG. 13 ). In this embodiment, backing layer  26  is preferably a heavier and more resilient structure than face layer  12  so that backing layer  26  does not collapse as a result of the dense needling action.  
         [0062]     Referring to  FIGS. 14-17 , another embodiment of the composite material  10  in accordance with the present invention is illustrated wherein face layer  12  is an undulated, gathered or folded structure with the plurality of fibers disposed in a gathered layer forming a plurality of downwardly facing loops  40  disposed at top surface  16  and descending from top surface  16  to bottom surface  18  and a plurality of upwardly facing loops  42  disposed at bottom surface  18  and ascending through face layer  12 .  
         [0063]     Suitable gathered structures include creped webs, microfolded webs, non-wovens, wovens, and knits. The structures also include webs, non-wovens, knits and wovens that are stitched with shrinkable yarns and post-shrunk to form folded structures. Suitable shrinkable yarns include stretched elastic yarns, partially oriented yarns, and flat, fully oriented yarns heated near the melting points of the yarns to cause the yarns to shrink. Polyolefin yarns are also suitable for shrinking 5-20° C. below their melting points. Face layer  12  can also include a plurality of secondary non-shrinking yarns (not shown) in contact with the stitching substrate. These secondary yarns can be stitched-in or laid-in yarns.  
         [0064]     As illustrated in  FIG. 15 , face layer  12  is a stitchbonded layer that includes a buckled stitching substrate  44  containing the plurality of fibers and a substantially planar network of shrinkable yarns  46  stitched to the stitching substrate. To produce a relatively smooth surface, the stitching frequency is relatively high in both directions (gauge and CPI), between about 6 stitches per inch and about 30 stitches per inch, preferably between about 10 stitches per inch and about 30 stitches per inch. In addition, face layer  12 , before being folded or gathered, has a fabric basis weight ranging from about 25 gm/m 2  to about 150 gm/m 2 . After folding and gathering, face layer has a fabric basis weight ranging from about 100 gm/m 2  to about 600 gm/m 2  and a folded frequency ranging from about 12 folds per inch to about 60 folds per inch. In addition, the thickness of face layer  12  is from about 0.5 mm to about 2 mm thick after folding.  
         [0065]     In an alternative embodiment as is illustrated in  FIGS. 18-19 , adhesive layer  22  can be integrated within the stitch-bonded structure of face layer  12 . In this embodiment, adhesive layer  22  can be a shrinkable layer that assists in creating the gathered structure of face layer  12 . Suitable adhesive layers include polyolefin films that shrink at about 130° C. to about 160° C. by a factor of about 1.3 to about 2.2 without melting. Suitable gathering frequencies and fabric weights for this arrangement are the same as for the embodiment illustrated in  FIGS. 14 and 15 . Suitable stitch-bonded structures of face layer  12  are disclosed in common owned, co-pending patent application entitled “Stitch-bonded and Gathered Composites and Methods for Making Same,” by the same inventor as the present invention and filed on the same day as this patent application.  
         [0066]     In order to make the composite material  10  of the embodiment illustrated in  FIGS. 14-17 , stitching substrate  44  containing the plurality of fibers is selected and stitchbonded using shrinkable yarn  46  in accordance with the desired fabric weight and gathered density,  FIG. 14 . Shrinkable yarn  46  is then shrunk to produce the gathered fabric structure,  FIG. 15 . Adhesive layer  22  is then brought into contact with bottom surface  18  of gathered face layer  12  and embedded into face layer  12  to form a two-layer laminate. Adhesive layer  22  is embedded into face layer  12  by applying heat and pressure. Although adhesive layer  22  is preferably in direct contact with the technical bottom surface  18  of face layer  12 , adhesive layer  22  may alternatively be placed in direct contact with the technical top surface  16  of face layer  12 . If a three layer laminate is being made, backing layer  26  is brought into contact with adhesive layer  22  prior to application of the heat and pressure so that adhesive layer  22  also penetrates into backing layer  26 ,  FIGS. 16 and 17 .  
         [0067]     In another embodiment as is illustrated in  FIG. 33 , adhesive layer  22  alone can be integrated within the stitch-bonded structure of face layer  12  without stitching substrate  44 . In this embodiment, adhesive layer  22  is preferably constructed from an adhesive material that is capable of being activated post-stitchbonding, i.e. post-activated, without appreciable shrinkage. Suitable adhesive materials for adhesive layer  22  in this embodiment include thermoplastic films, among others. In one embodiment, adhesive layer  22  is a polyethylene film. Adhesive layer  22  is stitchbonded using one or more yarns  47 .  
         [0068]     In this embodiment stitching yarn  47  forms the fibrous face layer of the composite. Yarn  47  forms a plurality of underlaps  49  located on the technical back of face layer  12  and forming fibrous bottom surface  18  of face layer  12 . In one embodiment, the technical back is substantially fully covered with underlaps  49 . In addition, yarn  47  forms a plurality of overlaps  51  located on the technical front of face layer  12  opposite the underlaps  49  and forming fibrous top surface  16  of face layer  12 . Therefore, adhesive layer  22  is disposed between top surface  16  and bottom surface  18 . In addition, underlaps  49  and overlaps  51  include a plurality of common legs  53  extending through adhesive layer  22 , and yarn  47 , including underlaps  49  and overlaps  51 , are anchored in place by post-activating adhesive layer  22  following stitchbonding. Suitable materials for yarn  47  do not shrink substantially during post-activation of adhesive layer  22  or subsequent lamination or embossing of face layer  12 . Therefore, yarn  47  does not gather.  
         [0069]     In one embodiment, face layer  12 , containing ungathered, stitchbonded adhesive layer  22  and yarn  47 , can be laminated to backing layer  26 . Suitable methods for laminating face layer  12  to backing layer  26  are described herein. In one embodiment, underlaps  49  forming fibrous bottom surface  18  are brought into contact with backing layer  26 , and heat and pressure are applied. Sufficient heat and pressure can be applied so that underlaps  49  become embedded in adhesive layer  26 . In addition, backing layer  26  can be embedded in adhesive layer  22 .  
         [0070]     In one embodiment, the pile or depth of second or outer fibrous layer  59  is defined by the amount of yarn in each overlap  51 , since adhesive layer  22  does not shrink substantially during post-activation. Alternatively, additional depth or texture can be applied to fibrous top layer  16  by embossing stitchbonded, post-activated face layer  12 . Suitable methods for embossing are described in co-pending and co-owned U.S. patent application Ser. No. 10/611,470, which is incorporated herein by herein in its entirety.  
         [0071]     Embossing can be performed on face layer  12  alone or in combination with laminating face layer  12  to backing layer  26 . In one embodiment, fibrous top surface  16  of face layer  12  is pattern-embossed to form a three-dimensional textured structure. The three-dimensional textured structure includes depressed areas and elevated areas. Within the depressed areas, activated adhesive anchors yarn  47  within overlaps  51  of fibrous top surface  16 , by embedding an adequate amount of yarn  47  in post-activated adhesive layer  22 .  
         [0072]     In one embodiment, post-activated adhesive may fully embed all yarns  47  in the depressed areas. Due to compression and embedding of yarns  47  in the post-activated adhesive, the depressed areas are primarily thin, dense and substantially oriented in an “x-y” direction, i.e., parallel to the plane of face layer  12 . Yarns  47  in fibrous top surface  16  in the elevated areas are substantially free of post-activated adhesive, although some surface interaction between fibrous top surface  16  and adhesive layer  22  in the inner strata facing adhesive layer  22 , i.e., the backside, is permitted. In regions near the peak of the elevated areas, yarns  47  are preferably disengaged from the post-activated adhesive. Accordingly in the elevated areas, yarns  47  of fibrous top surface  16  are capable of moving relative to each other, and maintain a “textile feel” subject to any preexisting bonding or entanglement in fibrous top surface  16 .  
         [0073]     In accordance with another aspect of the present invention, yarns  47  from fibrous top surface  16  immediately adjacent to the depressed areas may be bonded by a portion of the post-activated adhesive. In these clusters, the post-activated adhesives do not anchor yarns  47  of fibrous top surface  16 , but provide some structural rigidity to these yarns  47 . Due to the increased structural rigidity, yarns  47  in these cluster areas are advantageously oriented on a diagonal between the x-y plane of face layer  12  and a “z-direction” that is normal to the x-y plane. Yarns  47  in the cluster areas form an angle of less than about 45° away from the z-direction, and more preferably less than about 30° from the z-direction. This upstanding feature of yarns  47  in the cluster areas provides upstanding loop-like formations in yarns  47  in the elevated areas. Hence, these loops are anchored in the depressed areas, upstanding in the cluster areas, and bended or looped in the elevated areas.  
         [0074]     The relative freedom of movement of yarns  47  in the elevated areas allows face layer  12  to retain a good amount of textile appearance and feel. The depressed areas anchor yarns  47 , and provide enhanced surface stability, the ability to maintain its texture, breaking strength and resistance to abrasion. Additionally, when the optional backing layer  26  is used, the post-activated adhesive anchors yarns  47  of fibrous bottom surface  18  and of fibrous top surface  16  to the backing layer in the depressed areas, and backing layer  26  further enhances the ability of composite material  10  to retain its mainly planar configuration in response to ambient temperature and humidity changes. Upward oriented loops resulting from adhesive clustering at the edges of the depressed areas simulate the plush textile feel and sculpted appearance of pile fiber structured fabric.  
         [0075]     In another embodiment as illustrated in  FIGS. 20-23 , face layer  12  is a thin and dense gathered, pattern bonded layer containing face layer substrate  50  containing a plurality of fibers and shrinkable sublayer  52  attached or bonded to face layer substrate  50  with a spaced pattern of a plurality of discrete bonds  54 ,  FIG. 21 , placed at frequencies similar to the stitch frequencies of the embodiments illustrated in  FIGS. 14-17 . Heated pattern bonding tool  55  is used to produce bonds  54 . Face layer  12  is a fibrous web or fabric having a total buckled thickness of from about 0.5 mm to about 2 mm. Shrinkable sublayer  52  is preferably relatively open to allow the penetration of the thermoplastic or thermoset adhesive from adhesive layer  22  into face layer  12 . As with other embodiments of the present invention, thermoset or thermoplastic adhesives may benefit from the pre-application of adhesive layer  22  to one or both mating surfaces. Thermoplastic lamination may also benefit from preheating to accelerate the lamination process.  
         [0076]     As shown in  FIGS. 24-26 , adhesive layer  22  can be integrated into the structure of face layer  12  before substrate  50  is bonded to shrinkable sublayer  52 . In order to be integrated into face layer  12 , adhesive layer  22  is placed in direct contact with shrinkable sublayer  52  such that shrinkable layer  52  is disposed between adhesive layer  22  and substrate  50 ,  FIG. 24 . In this embodiment, adhesive layer  22  is preferably a shrinkable layer. The three layers are then bonded together with the discrete bonds  54 ,  FIG. 25 . Following bonding, shrinkable sublayer  52  and, if applicable, adhesive layer  22  are shrunk to produce gathered face layer  12 ,  FIG. 26 .  
         [0077]     In order to make the composite material in accordance with the arrangements illustrated in  FIGS. 20-23 , fibrous substrate  50  is selected and shrinkable substrate  52  placed in contact with fibrous substrate  50 ,  FIG. 20 . Fibrous substrate  50  and shrinkable substrate  52  are then bonded together in a pattern similar in frequency to those depicted in  FIGS. 14-19  in accordance with the desired fabric weight and gathered density. Suitable methods for pattern bonding these layers together include applying heated pattern plate  55  containing the desired pattern to top surface  56  of substrate  50 ,  FIG. 21 . Shrinkable substrate  52  is then shrunk to produce the gathered face layer structure,  FIG. 22 . Adhesive layer  22  is then brought into contact with bottom surface  18  and embedded into face layer  12  for example by applying heat and pressure. If a three layer laminate is being made, backing  26  is brought into contact with adhesive layer  22  prior to application of the heat and pressure so that adhesive layer  22  also penetrates into backing layer  26 ,  FIG. 23 .  
         [0078]     In another embodiment in accordance with the present invention as illustrated in  FIG. 3 , face layer  12  is a reversed knit or woven pile fabric layer. Suitable reversed knit or woven pile fabrics include those used to prepare velours or velvets. Pile side  58  of face layer  12  is sufficiently long to provide for adequate embedding of adhesive layer  22  into face layer  12  to stabilize face layer  12 . Suitable fabrics have basis weights that range from about 4 oz/yd 2  to about 16 oz/yd 2 , preferably about 6 oz/yd 2  to about 12 oz/yd 2  (about 200 gm/m 2  to about 400 gm/m 2 ). As in the case of surface layers  12  in accordance with the present invention, fabric face layer  12  provides a durable and decorative surface that utilizes finer and softer fibers that can be applied over backing layer  26  containing lower-cost, stiffer fibers to provide cushion, body, and dimensional stability.  
         [0079]     In order to make composite material  10  in accordance with the embodiment of  FIG. 3 , knit or woven pile fabric face layer  12  is selected and adhesive layer  22  is brought into direct contact with bottom surface  18  of face layer  12 . Adhesive layer  22  is then embedded into fabric face layer  12 , for example by the application of heat and pressure. If a three layer arrangement is desired, backing layer  26  is brought into direct contact with adhesive layer  22  before adhesive layer  22  is embedded into fabric face layer  12  so that adhesive layer  22  will also embed or penetrate into backing layer  26 .  
         [0080]     Referring to  FIGS. 27 and 28 , when face layer  12  is a knit fabric, face layer  12  contains a plurality of overlaps  60  on top surface  16  and a plurality of underlaps  61  on bottom surface  18 . In order to provide for stronger bonding between knit fabric face layer  12  and adhesive layer  22 , underlaps  61  can be cut, sanded, brushed or sheared at bottom surface  18  to produce a plurality of cut and raised fibers  62 . When laminated to adhesive layer  22 , adhesive layer  22  will embed into fabric face layer  12  throughout the area of cut and raised fibers  62 . This embodiment utilizes many different kinds of knits. Suitable knits contain underlap loops  61  that can be cut and raised on back surface  18  without affecting the texture of top surface  16 .  
         [0081]     Referring to  FIGS. 29 and 30 , face layer  12  contains a woven fabric having a plurality of warp yarns  64  and a plurality of weft yarns  66 . Weft yarns  66  have been cut, sanded, brushed or sheared on one surface of woven fabric face layer  12  in a manner that leaves yarn overlaps  68  of interconnecting warp yarns  64  intact and produces a plurality of cut and raised fibers  62  at bottom surface  18 .  
         [0082]     In order to make a composite material in accordance with the embodiments illustrated in  FIGS. 27-30 , a knit or woven face layer  12  is selected and the pile loop side for the knit fabric or one side of the woven fabric is sanded or cut to produce cut and raised fibers  62 . Adhesive layer  22  is then brought into direct contact with cut and raised fibers  62  and embedded into face layer  12 . Adhesive layer  22  can be embedded by the application of pressure and heat. If a three layer embodiment is desired, backing layer  26  is brought into contact with adhesive layer  22  before adhesive layer  22  is embedded into face layer  12  so that adhesive layer  22  will also penetrate into backing layer  26 .  
         [0083]     Since knit or woven face layer  12  is being cut or abraded, which weakens the structural integrity of the fabric, face layer  12  can be stabilized before being cut or sanded to assist in preserving the knit or woven structure during cutting or shearing. Stabilization or immobilization can be achieved by attaching a stabilizing sheet or a temporary layer of adhesive to top surface  16  prior to cutting, sanding or abrading bottom surface  18 . Following cutting, lamination of face layer  12  to the other layers can be performed with the face stabilizer left in place or removed.  
         [0084]     In another embodiment of stabilizing face layer  12  as illustrated in  FIGS. 31 and 32 , face layer  12  can be stabilized on high friction roller  70 . As illustrated, a continuous feed of face layer  12  from face layer roll  72  is introduced onto high friction roller  70 . Face layer  12  is then exposed to sanding roller  74 , brushing roller  76  or napping roller  78  producing cut and raised fibers  62  while stabilizing top surface  16 . Backing layer  26  and adhesive layer  22  are brought into contact with each other and heated and then laminated to face layer  12  while face layer  12  is still immobilized on high friction roller  70 . Optionally, roller  70  may be heated. The finished composite material is then collected on take-up roller  80 . Adhesive layer  22  can be introduced as a continuous sheet,  FIG. 31 , applied to backing layer  26  using a spray heads  82 ,  FIG. 32 , or applied to backing layer  26  as a foam  84  that is then doctor knifed  86  to the desired thickness,  FIG. 32 .  
       EXAMPLES  
     Example 1  
       [0085]     A blend of 80% 1.5 denier 1.5 inch polyester fibers and 20% 1.5 denier 1.5 inch polypropylene fibers is carded and lapped into a structure weighing approximately 8 oz/sq.yd. This face layer is then needled from one side only with 1,500 penetrations/sq.in. forming a dense surface and a very fur-like backface with many free ends and loops, as shown in  FIG. 6 .  
         [0086]     A second blend of 80% 15 denier, 1.5 inch cut polyester and 20% 1.5 denier 1.5 cut polypropylene fiber is carded and lapped into a 24 oz/sq.yd batt and needled with 300 penetrations per square inch from one face to form the backing layer.  
         [0087]     A dual layer of 0.05 inch thick polyethylene utility films is placed between the face layer and the backing layer, with the needled sides of the face layer and the backing on the outside and pressed with a plate heated to about 200 degrees C. placed against the face layer, at 1000 psi for 3 seconds. The plate facing the backing is at room temperature. The product is solidly laminated with all free fiber ends embedded in the molten polyethylene. Adhesive penetrates the two layers, but leaves a thickness of face layer approximately 1 mm thick free of adhesive. Delamination cannot be achieved without damage to the face or backing layers. The surface is smooth, durable and traffic-wear resistant with a textile feel and improved edge-fraying resistance.  
       Example 2  
       [0088]     The face layer of Example 1 is needled into the adhesive layer before laminating onto the backing layer. The stability of the surface is superior to Example 1. Delamination without destroying the layers is even more difficult. The surface is fibrous, smooth, free of adhesive and traffic-wear and edge-fraying resistant. The fibrous height above the adhesive penetration is approximately 0.9 mm.  
       Example 3  
       [0089]     The needled face layer of Examples 1 and 2 is needled directly through the dual adhesive layer and into the backing ( FIG. 12 ) before the hot pressing process. The product has a textile feel and excellent durability and is delamination resistant.  
       Example 4  
       [0090]     A non-woven fabric containing commercial polyester Sontara® spunlaced Style 8034 (20 g/m 2 ), sold by E. I. DuPont de Nemours, is stitched with P.O.Y. polyester yarn (155 denier/34 filament) using a stitch pattern of 1,0/3,4 at 14 gauge and 12 cpi. After stitching the product is subjected to 190 degrees C. for 30 seconds within a tentering frame, allowing it to shrink by a ratio of 1.7/1 both in the machine and cross directions. It forms a thin and dense undulated folded fabric structure as shown in  FIG. 15 . This fabric is placed over the dual layers of adhesive and backing of Example 1 and laminated as described in Example 1. The composite is very stable and traffic-wear resistant and has a textile feel with improved resistance to edge-fraying. Loop density is approximately 22/inch in both directions and loop height above the adhesive penetration is approximately about 1 mm.  
       Example 5  
       [0091]     The stitching bonding step for the face layer of Example 4 is repeated with an additional layer of 5.5 mil thick polyethylene adhesive film placed over the Sontara® nonwoven. After shrinking by a ratio of 1.6/1 in both directions by subjecting it to 150 degrees C. for 30 seconds within a frame, a buckled face layer containing an added layer of polyethylene on its technical back is produced ( FIG. 19 ). The composite is laminated to the backing of Example 1 under the same conditions with the same excellent results.  
       Example 6  
       [0092]     In this example, a folded layer produced by shrinking a dual shrinkable/non-shrinkable laminate is illustrated. A buckled face layer is constructed by intermittently “tacking” a layer of Style 8003 spunlaced non-woven polyester Sontara® (1.9 oz/yd 2  or about 50 gm/m 2 ) to a shrinkable sublayer consisting of a carded web of polypropylene staple weighing 30 gm/m 2 . The bonding pattern consists of elevated lines 0.5 mm thick extending across every 2 mm. Tacking is preformed using a heated patterned plate that is heated to 200 degrees C. and placed on the polyester side using 1000 psi for about 2 seconds. The polypropylene side rests against a room temperature steel plate.  
         [0093]     Upon heating the composite to 150 degrees C., the polypropylene layer shrinks to approximately 67% of its initial length, producing an undulated structure ( FIG. 22 ). This undulated face layer is placed over a dual layer of 5.5 mil thick polyethylene over the same backing used in Examples 1 and pressed in the same manner to produce a very coherent laminate with a textile feel, and improved edge-fraying resistance.  
       Example 7  
       [0094]     In this example, a folded layer containing a shrinkable adhesive layer, produced by pattern bonding and shrinking is illustrated. The process of Example 6 is repeated with a layer of polyethylene adhesive placed under the spunlaced sheet before tacking to the shrinkable backing ( FIG. 24 ). The assembly is pretacked and shrunk at 150 degrees C. to produce the composite face and adhesive layer.  
         [0095]     Subjecting this composite face/adhesive layer to the same lamination process in Example 6 over the same backing resulted in excellent adhesion, surface stability and edge fraying resistance.  
       Example 8  
       [0096]     In this example, a face layer consisting of commercial velour knit is applied with the pile face down against the adhesive layer. A commercial knit nylon velour fabric that was 1.1 mm thick and weighed 12.8 oz/yd 2  was laminated to the backing described above using the 5.5 mil polyethylene film described above, by pressing from one face only with a platen at 200 degrees C. for 1 second with the pile facing the adhesive film. Fabric thickness above the adhesive penetration line was approximately 0.9 mm. Excellent adhesion, surface stability and textile hand resulted. The product was highly resistant to edge fraying.  
       Example 8A  
     Prior Art  
       [0097]     The velour knit was laminated with the pile face up. Adhesion and edge fraying resistance were not achieved until pressure and time were increased over 3 seconds with some adhesive rising near the top of the face layer. This example is outside the scope of the present invention.  
       Example 9  
     Prior Art  
       [0098]     This example illustrates how a commercial cotton denim fabric that does not respond well to thermoplastic lamination can be converted to produce high-performance composite in accordance with the present invention.  
         [0099]     A commercial woven cotton fabric weighing 12.8 oz/yd 2  was laminated to the backing described above using the dual polyethylene films described above in a heated press. Top surface temperature was varied between 180 and 230 degrees C. Pressure at each step was varied between 150 and 10,000 psi, and the pressing time at each temperature combination was between about 0.5 and about 3 seconds. Lamination without relative ease of delamination was not achieved without penetrating the woven with polyethylene adhesive in spots or over the entire surface area. Surface stability versus traffic wear resistance also could not be achieved unless the adhesive resin rose to the top of the face layer. The cut edges of this composite frayed easily. This example is also outside the scope of the present invention.  
       Example 10  
       [0100]     The cotton woven mentioned in Example 9 was prestabilized by prelaminating onto commercial pressure sensitive Duct Tape. The stabilized product was held on a table top and hand sanded on the opposing face using a pad of 150 grit sandpaper until a uniform shade change indicated that practically all of the originally exposed yarns underneath were cut, and the face fabric assumed a highly open velvet-like surface. The fabric was then laminated onto the backing used in the above examples using a single layer of polyethylene, and pressing at 10,000 psi with the top plate heated to 180 degrees C. for 3 seconds. The pressure sensitive tape was removed, with minimal tape adhesive contamination remaining in a few spots on the surface. Excellent lamination, without a tendency to fray at cut edges and with an adhesive-free textile surface was achieved. The product had excellent surface stability versus traffic-wear resistance. The cut edges were highly resistant to fraying.  
         [0101]     Although specific forms of the invention have been selected for illustration in the drawings and the preceding description is drawn in specific terms for the purpose of describing these forms of the invention fully and amply for one of average skill in the pertinent art, it should be understood that various substitutions and modifications which bring about substantially equivalent or superior results and/or performance are deemed to be within the scope and spirit of the following claims.