TREATED FABRICS AND METHODS OF FORMING SAME
A finished composite material. The material includes a substrate having back and front surfaces, a film layer having first and second surfaces, and a backcoat layer having first and second surfaces. The first surface of the film layer is applied to the back surface of the substrate. The first surface of the backcoat layer is applied to the second surface of the film layer. The backcoat layer includes a non-acrylic binder and a flame retardant material.
1 . A finished composite material comprising:
a protector layer having back and front surfaces;
an adhesive layer having first and second surfaces, the first surface of the adhesive layer applied to the back surface of the protector layer, the adhesive layer formed of a number of discrete and non-continuous regions;
a film layer having first and second surfaces, the first surface of the film layer applied to the second surface of the adhesive layer; and
a backcoat layer having first and second surfaces, the first surface of the backcoat layer applied to the second surface of the film layer, the backcoat layer including a non-acrylic binder and a flame retardant material.
2 . The finished composite material of claim 1 , wherein the flame retardant material is a non-halogenated flame retardant material.
3 . The finished composite material of claim 1 , wherein the number of discrete and non-continuous regions form a number of non-adhesive regions therebetween configured to not resist flexing of the protector layer, film layer and backcoat layer.
4 . The finished composite material of claim 3 , wherein the adhesive layer includes a polyurethane (PUR) adhesive.
5 . The finished composite material of claim 1 , wherein the protector layer, the backcoat layer and/or the film layer includes a flame retardant or burn-resistant material.
6 . The finished composite material of claim 1 , wherein the film layer is formed of a thermoplastic polyurethane (TPU) material.
7 . (canceled)
8 . The finished composite material of claim 1 , wherein the backcoat layer includes a phase change material.
9 . The finished composite material of claim 1 , further comprising a fire retardant nonwoven layer having first and second surfaces, the first surface of the fire retardant nonwoven layer applied to the second surface of the backcoat layer.
10 . A finished composite material comprising:
a protector layer having back and front surfaces and formed of a textile material;
a backcoat layer having first and second surfaces including a non-halogenated fire retardant polymer; and
a film layer situated between the protector layer and the backcoat layer the backcoat layer directly applied to the film layer.
11 . The finished composite material of claim 10 , wherein the backcoat layer including a non-acrylic binder and a flame retardant material.
12 . The finished composite material of claim 11 , wherein the flame retardant material is a non-halogenated flame retardant material.
13 . The finished composite material of claim 10 , wherein the film layer is formed of a thermoplastic polyurethane (TPU) material.
14 . The finished composite material of claim 10 , wherein the film layer includes a marking to authenticate a source of the finished composite material.
15 . The finished composite material of claim 10 , wherein the backcoat layer includes a phase change material.
16 . (canceled)
17 . The finished composite material of claim 10 , wherein a hydrostatic resistance of the finished composite material is at least 100 cm water column pressure.
18 . A method of producing a finished composite material, the method comprising:
applying a film layer to a protector layer with a hot melt adhesive using a lamination process to form an adhesive layer having a number of discrete and non-continuous regions; and
applying a backcoat layer to a side of the film layer opposite the adhesive layer,
the backcoat layer including a non-acrylic binder and a flame retardant material.
19 . (canceled)
20 . (canceled)
21 . The method of claim 18 , wherein the lamination process is a roto gravure lamination process.
22 . The method of claim 418 , wherein the hot melt adhesive is a reactive polyurethane (PUR) adhesive.
23 . The method of claim 18 , wherein the flame retardant material is a non-halogenated flame retardant material.
24 . The finished composite material of claim 3 , wherein the number of non-adhesive regions include an interface between the back surface of the protector layer and the first surface of the film layer such that the back surface of the protector layer touches the first surface of the film layer at the interface.
25 . The finished composite material of claim 3 , wherein the finished composite material has a stiffness of 1,400 to 6,000 grams-force according to an ASTM 4032-08 (2012) test for pliability.
26 . The finished composite material of claim 1 , wherein the film layer includes a marking to authenticate a source of the finished composite material.