Patent Publication Number: US-2006019563-A1

Title: &#34;Barrier&#34; substrate

Description:
PRIORITY CLAIM  
      This application claims the benefit of priority to provisional application No. 60/486,668, filed in the United States on Jul. 12, 2003, and titled “Method and Apparatus to Create Laminated Barrier Substrates for Home Fabrics and Upholstery”.  
     References Cited  
     
       
         
           
               
             
               
                   
               
               
                   
               
               
                 U.S. Patent Documents 
               
               
                   
               
             
            
               
                   
               
            
           
           
               
               
               
               
            
               
                 4525409 
                 June 1985 
                 Elesh. 
                   
               
               
                 4632860 
                 December 1986 
                 D&#39;Antonio et al. 
               
               
                 4772281 
                 September 1988 
                 Armstead 
                 604/358. 
               
               
                 5283112 
                 February 1994 
                 Krishnan. 
               
               
                 5306536 
                 April 1994 
                 Moretz et al. 
               
               
                 5391418 
                 February 1995 
                 Strongwater 
                 428/171. 
               
               
                 5514459 
                 May 1996 
                 Blauer et al. 
               
               
                 5527600 
                 June 1996 
                 Frankosky et al. 
               
               
                 5565265 
                 October 1996 
                 Rubin et al. 
               
               
                 5631074 
                 May 1997 
                 Herlihy, Jr. 
               
               
                 5677028 
                 October 1997 
                 Ravella 
                 428/102. 
               
               
                 5747392 
                 May 5, 1998 
                 Rubin 
               
               
                   
               
            
           
         
       
     
                                     Foreign Patent Documents                                                    0541206B1   October 1999   EP.           1339859   December 1973   GB.           WO 80/01031   May 1980   WO.           9729909   August 1997   WO.                        
 Other References Cites: 
 
 US Patent Publication No. US-2004-006827-A1, Dated Jan. 15, 2004 
 
 U.S. patent application Ser. No. 10/611,746, Dated Jun. 30, 2003
 
    
    
     BACKGROUND OF INVENTION  
      This application is in part a continuation of patent application Ser. No. 10/896,854, Filed Jul. 23, 2004, Titled “A Water and Stain  
      Repellent Barrier Substrate”.  
      There are several patents and publications on water and stain repellent textiles. The existing methods discussed in this application range from the application of wax coatings to polymeric films or multiple coatings of latex combined with polymeric films. Most of the existing technology would be better classified as repellent to stains and water and not be classified as a “barrier” substrate.  
      A waterproof and stain repellent “barrier” substrate as used herein means to support a column of water for several, minutes without water penetration through the fabric and not allow the absorption of stains or moisture by the fibers of the exposed surfaces as defined in this invention.  
     DESCRIPTION OF THE RELATED ART  
      The related art of interest describes various waterproof fabrics for outdoor and Indoor use. None of the related art addresses the need for a light weigh low cost fabric type “barrier” substrate. The textile type “barrier” products are now produced by applying multiple coatings of acrylic and other copolymers to a substrate treated with fluorocarbons. The method requires multiple passes through very large energy consuming dryers that are polluting the environment. In addition to being very expensive the current method produces a very heavy and stiff product. By this invention a lightweight more durable product can be produced at half the energy now required thus allowing US textiles to compete world wide.  
      U.S. Pat. No. 5,283,112 issued on Feb. 1, 1994, to Sundaram Krishnan describes the making of waterproof breathable fabric laminates from polyurethane membrane bonded between woven or non-woven nylon fabric layers and the products useful for tenting and rainwear. The waterproof polyurethane added product is distinguishable for its emphasis on being breathable and mostly limited to breathable polyurethane compounds which would not be suitable for a barrier product as in this present invention.  
      U.S. Pat. No. 5,527,600 issued on Jun. 18, 1996, to Michael S. Frankosky et al. describes a bonded polyester fiberfill batting with a sealed outer surface by coating with an acrylic resin. The batting is useful for filling pillows, cushions, bedding materials, and in apparel. The batting is distinguishable for its non-laminated structure.  
      U.S. Pat. No. 5,565,265 issued on Oct. 15, 1996, to Craig A. Rubin et al. describes a liquid and stain resistant antimicrobial fabric made by repeatedly coating a polyester fabric in separate steps with an aqueous composition containing an acrylic copolymer, a fluorochemical and a biocide/mildewed. The antimicrobial agents disclosed are hereby incorporated by reference. The antimicrobial fabric is distinguishable for its limitation to a single substrate coated with multiple coatings and emphasis on polymeric films which would not be suitable for a barrier product as in this present invention.  
      U.S. Pat. No. 4,525,409 issued on Jun. 25, 1985, to James N. Elesh describes a tightly woven nylon or polyester treated fabric for producing bedding fabrics. The tightly woven taffeta or ripstop weave cloth is coated with urethane water repellant, a bacteriostatic and fungistatic agent, a fire retardant, and an anti-static agent. The antimicrobial compositions are incorporated by reference. The fabric is distinguishable by the addition of a plurality of agents to the single layer of the tightly woven fabric.  
      U.S. Pat. No. 4,632,860 issued on Dec. 30, 1986, to John P. D&#39;Antonio et al. describes a waterproof, moisture-breathable, non-macerating, and hypoallergenic fabric by coating a substrate layer containing natural or synthetic fibers with a basecoat of an acrylic polymer and pigment, and a topcoat of either polyether urethane or silicone latex. The fabric is distinguishable for being a single coated layer.  
      U.S. Pat. No. 5,631,074 issued on May 20, 1997, to Daniel J. Herlihy, Jr. describes a two- or three-layer waterproof breathable fabric for outdoor athletic apparel comprising a shell fabric having a blend of polypropylene filaments and spandex fibers, a waterproof membrane of a copolyether ester laminated to the shell fabric, and  
      optionally, a crepe or mesh lining. A silicone coating may be applied on the shell fabric. The fabric is distinguishable for its waterproofing elastic quality used for a surfer dry suit and not be suitable for a barrier product as in the present invention.  
      U.S. Pat. No. 5,306,536 issued on Apr. 6, 1994, to Herbert L. Moretz et al. describes a multi-layer moisture management fabric comprising four layers for making undergarments for incontinent people. The shell fabric is conventional undergarment material, the second layer is a thick hydrophilic storage layer of nylon fibers, the third layer is a thin nylon transport layer, and the fourth innermost layer is a knitted or woven hydrophobic polyester layer. The third and fourth layers can be combined. The fabric is distinguishable for its lack of cohesiveness between layers as required in the present invention.  
      U.S. Pat. No. 5,514,459 issued on May 7, 1996, to Stephen J. Blauer et al. describes a waterproof breathable lining for outerwear comprising a shell fabric of a plain weave of nylon, acrylic or polyester which is printed with a pattern of a terpolymer containing 12-30% urethane, 1% silicone and the remainder being acrylic. The terpolymer pattern is impregnated with a fluorocarbon release agent. The lining includes an intermediate outer synthetic polymer membrane (polyurethane, polyester ether and/or polytetrafluoroethylene), an inner synthetic polymer fabric (nylon or polyester weave or knit), and optionally, an outer synthetic polymer fabric (nylon or polyester weave or knit). The four- or five-layer shell fabric and lining composition would not be suitable for a barrier product as in the present invention.  
      P.C.T. Patent Application No. WO 80/01031 published on May 15, 1980, for Frankosky describes a fiberfill blend for thermal insulation in garments comprising 70-90% crimped polyester staple fiber (polyethylene terephthalate) and 10-30% crimped staple binder fiber (ethylene terephthalate/ethylene isophthalate copolyester with 25-75 wt. % slickened with a cured polysiloxane. The fiberfill blend is distinguishable for its emphasis on thermal quality rather than waterproofing.  
      None of the above inventions and patents, taken either singularly or in combination, is seen to describe the present invention as claimed. Thus, a stain and waterproof “barrier” fabric which is light in weight, economical, fabric like and multi-ply is desired.  
     SUMMARY OF THE INVENTION  
      The present invention relates to an improved waterproof barrier fabric useful for furniture, wall covering, and medical applications with optional antimicrobial properties.  
      It is a principal object of the invention to provide a stain and waterproof barrier substrate consisting of a layer laminated fabric. Top layer being a textile (woven or knit) substrate. Second layer being a film. The second layer provides the dual function of adhesive to top and bottom layers and provides the barrier. The third layer can be a non-woven substrate or a back coating of the second layer or left out completely creating a two layer laminate.  
      It is another object of the invention to provide a waterproof stain repellent fabric comprising a top layer of a material selected from the group consisting of man made fibers and natural fibers and mixtures thereof treated to be water and stain repellent with fluorocarbons as outline in U.S. Pat. No. 5,747,392 patent or U.S. patent application Ser. No 10/611,746, Dated Jun. 30, 2003.  
      In another aspect of the invention the third layer is an acrylic latex comprising a dispersion of polymers and/or copolymers of acrylic or acrylate functional monomers, optionally copolymerized with other ethylenically unsaturated monomers and back coated on to the second layer (being a film) after lamination process—creating a back coated laminate barrier substrate. 
    
    
     DETAILED DESCRIPTION  
      The present invention relates generally to an improved 2 or 3-ply stain and waterproof barrier fabric useful for furniture upholstery, wall coverings, restaurant table coverings and medical applications. The layers can be laminated by being made to come in continuous contact, and while in contact, pressure is applied between a blanket and a roller. The pressure is about 50 lbs/in·sup·2 (34 N/cm·sup·2) to about 60 lbs/in·sup·2 (41 N/cm·sup·2), with 60 lbs/in·sup·2 (41 N/cm·sup·2) preferred. Heat is also applied at about 380.degree. F. to about 430. degree. F. (193. degree. C. to 221. degree. C.), preferably at 420. degree. F. (216. degree. C.). The dwell time, (15 to 30 sec.) or time where heat and/or pressure are applied, is a time sufficient for the film layer to become soft enough to provide bonding but not losing its ability to provide a barrier to liquid supporting a column of water.  
      The second layer a film layer can be supplied in roll stock film to the heat and pressure lamination process or be extruded into film via die slot and hot melt technology and applied directly to the back of the top substrate at the lamination process with or without release paper on one side. Those skilled in the art will know other methods to laminate the layers as there are any number of ways and the above is merely representative of two methods.  
      The third layer, a back coating, is dried and cured in an oven at approximately 250 degrees F. to 350 degrees F. The amount of the back coating can vary from a skim coating (0.001 to 0.005 inches thick) to 15 percent of fabric weight. Back coating as used herein is applying a coating to the back or bottom side of a substrate as oppose to placing it on the face or top of a substrate, when one side is different from the other. This type application can vary but most common is to use a doctor blade or knife-edge adjusted to touch or nearly touch the substrate surface as described in U.S. Pat. No. 5,747,392.