IP Library Granted Patent US 6,936,327
Granted Patent B2
US 6,936,327 · App. 10/611,287 · Granted Aug 30, 2005

Stitch-bonded and gathered composites

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Quick Facts
Patent No.
US 6,936,327
App. No.
10/611,287
Granted
Aug 30, 2005
Kind
B2
Abstract

Disclosed herein is a composite comprising at least one heat shrinkable adhesive layer stitch-bonded with yarns, which shrink less than the adhesive layer or do not shrink, when the adhesive layer is exposed to heat. The stitch-bonded yarns form loops upstanding from the shrunk adhesive layer and the loops create a textured surface on the composite, and the composite is substantially inelastic after the adhesive layer is shrunk. The composite may further comprise at least one fibrous layer stitch-bonded to the shrinkable adhesive layer, and the fibrous layer is less shrinkable than the adhesive layer or is substantially non-shrinkable.

Claims (55)

1. A composite comprising at least one heat shrinkable layer stitch-bonded with a network of yarns wherein the shrinking temperature of the shrinkable layer is lower than the melting temperature of the stitch-bonded yarns, and wherein shrinkable layer shrinks and causes the stitch-bonded yarns to form loops emanating from the shrunk layer, and wherein the shrunk layer is substantially inelastic.

2. The composite of claim 1 , wherein the loops have a frequency of at least 10 per inch in at least one direction and a height of less than about 2.0 mm.

3. The composite of claim 1 , wherein the shrunk composite is dimensionally stable.

4. The composite of claim 1 , wherein the stretchability of the shrunken composite is less than about 20% strain under a 5 lb/inch pull on a 1 inch wide by 8 inch long strip of the composite.

5. The composite of claim 1 , wherein the heat shrinkable layer comprises a non-woven fabric, a woven fabric or a knit fabric.

6. The composite of claim 1 , wherein the heat shrinkable layer comprises a plastic film.

7. The composite of claim 1 , wherein the heat shrinkable layer is shrinkable by about 10% to about 50% in at least one direction.

8. The composite of claim 7 , wherein the heat shrinkable layer is shrinkable in two directions.

9. The composite of claim 1 , wherein the heat shrinkable layer is shrinkable by at least about 20% in at least one direction.

10. The composite of claim 9 , wherein the heat shrinkable layer is shrinkable in two directions.

11. The composite of claim 1 , wherein the yarns are substantially non-shrinkable.

12. The composite of claim 1 , wherein the yarn's comprise a flat filament yarn.

13. The composite of claim 1 , wherein the yarns comprise a staple-based yarn.

14. The composite of claim 1 , wherein the yarns comprise a bulked twisted filament yarn.

15. The composite of claim 1 , wherein the yarns comprise a composite staple/continuous filament yarn.

16. The composite of claim 1 , wherein the yarns comprise textured polymeric yarns.

17. The composite of claim 1 , wherein the yarns comprise composite flat and textured yarns.

18. The composite of claim 1 , wherein the yarns are stitched to the heat shrinkable layer in accordance with two or more distinct stitching patterns.

19. The composite of claim 1 , further comprising at least one fibrous layer stitch-bonded to the heat shrinkable layer.

20. The composite of claim 19 , wherein the fibrous layer is less shrinkable than the heat shrinkable layer.

21. The composite of claim 20 , wherein the fibrous layer is substantially non-shrinkable.

22. The composite of claim 20 , wherein the fibrous layer forms a second set of loops when the heat shrinkable layer shrinks.

23. The composite of claim 20 , wherein the fibrous layer is bonded to the heat shrinkable layer at locations proximate the stitching points.

24. The composite of claim 19 , wherein the fibrous layer is positioned on the technical front of the heat shrinkable layer.

25. The composite of claim 19 , wherein the fibrous layer is positioned on the technical back of the heat shrinkable layer.

26. The composite of claim 19 , wherein the fibrous layer comprises from about 10% up to about 50% low melt binder, the low melt binder bonding surface fibers within the fibrous layer.

27. The composite of claim 19 , wherein the fibrous layer comprises a non-woven layer, a woven layer, a knit layer or a stitch-bonded layer.

28. The composite of claim 19 , wherein the non-woven layer is a spunlaced nonwoven.

29. The composite of claim 1 , wherein the composite is stitch-bonded with a gauge from about 3 per inch up to about 22 per inch and a CPI from about 6 per inch up to about 24 per inch.

30. The composite of claim 1 , wherein the composite is stitch-bonded with a gauge from about 9 per inch up to about 22 per inch and a CPI from about 12 per inch up to about 24 per inch.

31. The composite of claim 1 , wherein the heat shrinkable layer is an adhesive layer.

32. The composite of claim 31 , wherein the adhesive layer comprises a thermoplastic adhesive.

33. The composite of claim 32 , wherein the thermoplastic adhesive comprises a polyolefin.

34. The composite of claim 1 further comprising an adhesive layer.

35. The composite of claim 34 , wherein the adhesive layer is stitch-bonded to the heat shrinkable layer.

36. The composite of claim 34 , wherein the adhesive layer is substantially non-shrinkable.

37. The composite of claim 34 , wherein the adhesive layer is shrinkable.

38. The composite of claim 31 , wherein the adhesive layer shrinks to a flat layer.

39. The composite of claim 31 , wherein the adhesive layer is activated to encase the vertical portions of the stitch-bonded yarns passing through the adhesive layer.

40. The composite of claim 1 , wherein the composite is laminated to a backing layer.

41. The composite of claim 1 , wherein the composite is embossed to a backing layer.

42. A composite comprising at least one heat shrinkable layer stitch-bonded with yarns that shrink less than the heat shrinkable layer when the composite is exposed to heat, wherein the stitch-bonded yarns form loops upstanding from the shrunk layer and the loops create a textured surface on the composite and wherein the composite is substantially inelastic after the heat shrinkable layer is shrunk.

43. The composite of claim 42 , wherein the heat shrinkable layer is an adhesive layer.

44. The composite of claim 42 further comprises an adhesive layer.

45. The composite of claim 44 , wherein the adhesive layer is substantially non-shrinkable.

46. The composite of claim 44 , wherein the adhesive layer is shrinkable.

47. The composite of claim 44 , wherein the adhesive layer is stitch-bonded to the heat shrinkable layer.

48. The composite of claim 42 , wherein the stitch-bonded yarns are substantially non-shrinkable.

49. The composite of claim 43 further comprising at least one fibrous layer stitch-bonded to the shrinkable adhesive layer.

50. The composite of claim 49 , wherein the fibrous layer is less shrinkable than the adhesive layer.

51. The composite of claim 49 , wherein the fibrous layer is substantially non-shrinkable.

52. The composite of claim 51 , wherein the fibrous layer forms a second set of loops when the adhesive layer shrinks.

53. The composite of claim 42 , wherein the stretchability of the composite is less than about 20% strain under a 5 lb/inch pull on a 1 inch wide by 8 inch long strip of the composite.

54. The composite of claim 53 , wherein the stretchability is less than about 10%.

55. The composite of claim 44 , wherein the adhesive layer is applied to the heat shrinkable layer.

Assignments (6)
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Sep 28, 2017
From: TEXTILE FLOORING INTERNATIONAL, LLC
To: J&J FLOORING GROUP, LLC
Reel/Frame 043726/0827 →
SECURITY INTEREST Recorded Apr 15, 2016
From: TEXTILE FLOORING INTERNATIONAL, LLC
To: BRANCH BANKING AND TRUST COMPANY
Reel/Frame 038293/0048 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Mar 1, 2016
From: DZS, LLC
To: TEXTILE FLOORING INTERNATIONAL, LLC
Reel/Frame 037863/0839 →
CHANGE OF NAME Recorded Jun 7, 2006
From: SWZ, LLC
To: SDZ, LLC
Reel/Frame 017746/0365 →
CHANGE OF NAME Recorded Jun 7, 2006
From: SDZ, LLC
To: DZS, LLC
Reel/Frame 017746/0369 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Jul 1, 2003
From: ZAFIROGLU, DIMITRI PETER
To: SWZ, LLC
Reel/Frame 014253/0111 →
Continuity (1)
Related Publication 20050003140A1 · Jan 6, 2005