Granted Patent B2

US 8,778,110 · App. 12/524,240 · Granted Jul 15, 2014

Abstract

Claims (27)

1. A method of manufacturing a composite textile, comprising:

unrolling a textile face layer from a first roll;

unrolling a non-woven backing layer from a second roll;

providing an adhesive to the non-woven backing layer;

activating the adhesive in a device;

positioning the textile face layer in contact with the adhesive to bond the textile face layer to the non-woven backing layer after activating the adhesive in the device and before passing the textile face layer and the non-woven backing layer between a first pair of rollers; and

passing the textile face layer and non-woven backing layer between the first pair of rollers to squeeze the textile face layer and non-woven backing layer together to create the composite textile.

2. The method of claim 1 wherein the textile face layer is a woven material.

3. The method of claim 1 further comprising passing the composite textile between a second pair of rollers and rolling the composite textile onto a third roll.

4. The method of claim 1 wherein the textile face layer is positioned in contact with the non-woven backing layer at a single guide roller.

5. The method of claim 1 wherein the device includes a heat source and the adhesive is activated by heat from the heat source.

6. The method of claim 5 wherein the device includes a flame for flame bonding the non-woven backing layer to the textile face layer.

7. The method of claim 1 wherein the device ultrasonically bonds the non-woven backing layer to the textile face layer.

8. The method of claim 1 wherein the adhesive is provided as a double sided adhesive film.

9. The method of claim 1 wherein the adhesive is applied to the non-woven backing layer while the non-woven material layer is in motion.

10. The method of claim 1 wherein the adhesive is applied to the textile face layer while the textile face layer is in motion.

11. A method of manufacturing a composite textile, comprising:

unrolling a woven textile face layer from a first roll and unrolling a single non-woven backing layer from a second roll, wherein the non-woven backing layer includes an adhesive material before being unrolled;

passing only the textile face layer and the non-woven backing layer between a first pair of rollers such that the textile face layer contacts the non-woven backing layer;

activating the adhesive material to bond the textile face layer and the non-woven backing layer together after passing the textile face layer and the non-woven backing layer between the first pair of rollers; and

passing the textile face layer and non-woven backing layer between a second pair of rollers to squeeze the textile face layer and non-woven backing layer together.

12. The method of claim 11 wherein the textile face layer is a woven material.

13. The method of claim 11 wherein the adhesive material is activated by a device located between the first and second pair of rollers that provides heat.

14. The method of claim 11 wherein the adhesive material is activated by pressure applied by the second pair of rollers.

15. The method of claim 14 further comprising rolling the composite textile onto a third roll after exiting the second pair of rollers.

16. The method of claim 11 wherein adhesive material is activated by a device located between the first and second pair of rollers that ultrasonically bonds the non-woven backing layer to the textile face layer.

17. The method of claim 11 wherein the adhesive material is a double sided adhesive film.

Assignments (9)