COMPOSITE FILM AND METHOD FOR FABRICATING SAME
A composite film comprises a polymer layer comprising polybutylene terephthalate loaded with from about 0.5 wt. % to about 15 wt. % of a pigment, and from about 0.5 wt. % to about 1.5 wt. % of a UV stabilizer, and a fabric substrate layer at least partially embedded in and bonded to the polymer layer.
1 . A composite film comprising:
a polymer layer comprising polybutylene terephthalate loaded with from about 0.5 wt. % to about 15 wt. % of one or more pigments, and from about 0.5 wt. % to about 1.5 wt. % of one or more UV stabilizers; and
a fabric substrate layer at least partially embedded in and bonded to the polymer layer.
2 . The composite film of claim 1 , wherein the polybutylene terephthalate has a melt flow rate from about 15 to about 30 at 250° C.
3 . The composite film of claim 1 , wherein the polymer layer comprises from about 0.1 wt. % to about 0.3 wt. % of one or more antioxidants.
4 . The composite film of claim 1 , wherein the one or more pigments comprise a white pigment.
5 . The composite film of claim 4 , wherein the white pigment comprises a titanium dioxide pigment.
6 . The composite film of claim 5 , wherein the titanium dioxide pigment has a loading of about 2 wt. % to about 15 wt. %.
7 . The composite film of claim 5 , wherein the titanium dioxide pigment comprises titanium dioxide particles with a silicone coating.
8 . The composite film of claim 1 , wherein the one or more pigments comprise a non-white pigment including one or more of: a gray pigment; a red pigment; an orange pigment; a yellow pigment; a green pigment; a blue pigment; a purple pigment; a violet pigment; a brown pigment; and a black pigment.
9 . The composite film of claim 1 , wherein the one or more pigments comprise a non-white pigment including one or more of:
a gray pigment;
a red pigment comprising cadmium selenide;
an orange pigment comprising cadmium sulfoselenide;
a yellow pigment comprising cadmium sulfide;
a green pigment comprising chromium (III) oxide;
a blue pigment comprising cobalt (II) stannate;
a purple pigment comprising cobalt orthophosphate;
a brown pigment comprising umber; and
a black pigment comprising carbon black.
10 . The composite film of claim 1 , wherein the fabric substrate layer comprises one or more non-woven fibers.
11 . The composite film of claim 1 , wherein the fabric substrate layer comprises one or more polyethylene terephthalate-based fibers.
12 . The composite film of claim 11 , wherein the polyethylene terephthalate-based fiber comprises at least one of: a polyethylene terephthalate fiber; a bi-component polyester fiber with a polyethylene terephthalate core and a co-polyester sheath; a bi-component fiber with a polyethylene terephthalate core and a polyolefin sheath; or a fiber blend comprising two or more of a polyethylene terephthalate fiber, a bi-component fiber with a polyethylene terephthalate core and a co-polyester sheath, a bi-component fiber with a polyethylene terephthalate core and a polyolefin sheath, or a polypropylene fiber.
13 . The composite film of claim 12 , wherein the polyolefin sheath comprises at least one of a polyethylene, a polypropylene, a polyethylene copolymer, or a polypropylene copolymer.
14 . The composite film of claim 1 , further comprising a first release film applied to a surface of the polymer layer.
15 . The composite film of claim 14 , wherein the surface of the polymer layer to which the first release film is applied has a glossy or mirrored finish.
16 . The composite film of claim 1 , wherein at least a portion of the fabric substrate layer protrudes from the polymer layer.
17 . The composite film of claim 16 , further comprising an additional layer bonded to at least the protruding portion of the fabric substrate layer, the additional layer comprising at least one of a rigid or substantially rigid support substrate; an adhesive; a sealant; and a lamination adhesion layer.
18 . The composite film of claim 17 , further comprising a second release film applied to the additional layer.
19 . The composite film of claim 17 , wherein the additional layer comprises the rigid or substantially rigid support substrate, the support substrate comprises at least one of a polypropylene, a polypropylene copolymer, a polyethylene, and a polyethylene copolymer.
20 . The composite film of claim 16 , wherein the protruding portion of the fabric substrate layer has a thickness of from about 0.025 mm to about 0.13 mm.