| WO2004005016A1 | 2004-01-15 | |||
| WO1995003173A1 | 1995-02-02 |
| EP0247797A2 | 1987-12-02 | |||
| US20060204731A1 | 2006-09-14 | |||
| FR2445765A1 | 1980-08-01 | |||
| AU536675B2 | 1984-05-17 | |||
| US20070082176A1 | 2007-04-12 | |||
| IT1255570B | 1995-11-09 | |||
| IT1256232B | 1995-11-29 | |||
| IT1255654B | 1995-11-09 | |||
| IT1256230B | 1995-11-29 | |||
| IT1255803B | 1995-11-16 | |||
| EP0584511A1 | 1994-03-02 | |||
| IT1327162B | ||||
| IT1277094B1 | 1997-11-04 |
| β CLAIMS 1. A composite product comprising a first layer of non- woven microfibre fabric and a second layer comprising at least one sheet of aluminium foil, wherein the first and second layers are bonded to each other. 2. A composite product according to claim 1, wherein the non-woven microfibre fabric comprises synthetic polymer microfibres embedded in a polymer matrix. 3. A composite product according to claim 1 or 2, wherein the non-woven microfibre fabric comprises polyester or polyamide microfibres embedded in a polyurethane matrix. 4. The composite product according to one or more of the preceding claims, comprising an adhesive layer or adhesive portions between the first and second layers in order to bond the two together. 5. The composite product according to one or more of the preceding claims, comprising a thermo-adhesive film applied between the first and second layers so that the first and second layers are bonded to each other by the thermo-adhesive film. 6. The composite product according to one or more of the preceding claims, comprising a thin layer of foam material applied between the first and second layers and melted by direct application of a flame so that the first and second layers are bonded to each other by the "flame" method. 7. The composite product according to one or more of the preceding claims, comprising : low melting-point thermoplastic resins applied between the first and second layers and brought to the: melted state by extrusion so that the first and second layers are bonded to each other by hot melt gluing. 8. The composite product according to one or more of the preceding claims, comprising thermosetting resins spread by engraved cylinders on the back of one of the two layers, preferably the first layer.. 9. The composite product according to one or more of the preceding claims, wherein the first and second layers are bonded together by applying an adhesive layer between the two layers and subsequently calendering the two layers. 10. The composite product according to one or more of the preceding claims, wherein the first and second layers are bonded together by a two-sided adhesive film applied cold between the two layers. 11. The composite product according to one or more of the preceding claims, wherein the second, aluminium layer comprises at least one sheet of adhesive aluminium foil. 12. The composite product according to one or more of the preceding claims, wherein the second, aluminium layer is adapted to allow relatively firm crinkling to be formed on the first layer of non-woven microfibre fabric. 13. The composite product according to one or more of the preceding claims, wherein the second, aluminium layer has a total thickness between 0.02 and 1 mm. 14. The composite product according to one or more of the preceding claims, wherein the first layer has a first surface which is treated, for_.example - by sanding, to give it an effect similar to that of suede, the first surface being the one opposite to the second layer. 15. The composite product according to one or more of the preceding claims, wherein the second layer can be moulded into a relatively, firm shape in order to reproduce creasing and/or crinkling and/or wrinkling. 16. The composite product according to one or more of the preceding claims, wherein the second, aluminium comprises two or more sheets of aluminium . foil and an adhesive layer interposed between two adjacent sheets , of aluminium foil. |
DESCRIPTION
This invention relates to a composite product.
More specifically, this invention is applicable in the furniture sector where non-woven microfibre fabrics are used. ..
Non-woven microfibre fabrics are known which comprise polyester or polyamide. microfibres embedded in a polyurethane matrix.
More specifically, these fabrics are very hard-wearing, provide effects similar to those of suede and are particularly suitable for furniture and upholstery.
Indeed, these fabrics are used as coverings for sofas, armchairs and auto interiors. These coverings confer softness and durability to the support they are applied to .
Generally speaking, however, they are limp or floppy fabrics which cover and adapt completely to the form to be covered.
More specifically, these fabrics are not capable of satisfying a need as yet unsatisfied in the sector, and that is, to provide structures that are relatively firm, for example creased and/or wrinkled, but nevertheless pleasant to the -touch, resistant, and modifiable in aesthetic appearance.
Such structures might be applicable both in the context of furniture and decoration, for example . to make cushions or other decorative structures having a soft surface offering a suede effect with relatively firm crinkles " and/or creases and/or wrinkles. Non-woven microfibre fabrics comprising polyester or polyamide microfibres embedded in a polyurethane matrix and the processes used to make them are described, for example in Italian patents 1255570, 1256232, 1255654, .1256230, 1255803 and in European patent 584511 to which reference is made for any further description of the fabric properties. More specifically, the components, the application examples and the related manufacturing processes are incorporated in this description by reference.
Further examples of components, applications and related manufacturing processes described in Italian patents No. 1327162 and 1277094 are incorporated in this description by reference.
In general terms, these non-woven microfibre fabrics are formed from synthetic polymer microfibres generally comprising polyester or polyamide.
More specifically,- a staple fibre is used to prepare a raw felt which is submitted to a needling process. After being treated with solvents, if necessary, and dried, a polymeric polyurethane is applied, preferably by dipping the raw felt in a polyurethane elastomer solution.
The manufacturing process and composition of the staple fibre, the solvents used, the manufacturing process and composition of the polyurethane elastomer and the impregnation and finishing process, as well as all the application examples are described in the aforementioned patents which are incorporated by reference in : this description.
Further features and advantages of this invention are : more apparent in the -non-limiting description of a preferred embodiment of a composite product, as shown in the accompanying drawings in which:.
- Figure 1 is a view from below of a composite product according to this invention;
- Figure 2 is a view from above of the composite product illustrated in Figure 1.:
With reference to the above, this invention relates to a composite product comprising a first layer 1 of non- woven microfibre fabric and a second layer 2 comprising at least one sheet of aluminium foil. The two layers are bonded to each other.
More in detail, the non-woven microfibre fabric comprises synthetic polymer microfibres embedded in a polymer matrix.
In still more detail, the non-woven microfibre fabric comprises polyester or polyamide microfibres embedded in a polyurethane matrix, with reference to the examples and processes incorporated herein by reference.
Advantageously, an adhesive layer or adhesive portions may be provided between the first and second layers in order to bond the two together.
According to one possible embodiment, . the first and second layers are bonded by any of several methods known in the trade, such as: gluing by means of thermo- adhesive film applied between the first and second layers, or bonding using the "flame" method, where the adhesive element is a thin layer of foam material melted by direct application of a flame, or ' hot-melt bonding, where the adhesive element consists of low melting point thermoplastic resins brought to the melted state by extrusion, or thermosetting resins subsequently spread by engraved cylinders on the back of one of the two layers, preferably, the microfibre layer.
Bonding of the two layers occurs by applying the cohesive agent described above (thermo-adhesive film, foam in the melted state, thermoplastic or thermosetting resins) between the two layers and then calendering the two layers.
Advantageously, it is also possible to use a two-sided adhesive film applied cold between the two layers, or a sheet of adhesive aluminium foil.
More specifically, the aluminium layer is adapted to allow relatively firm crinkles/creases to be formed on the first layer of non-woven microfibre fabric.
Preferably, the total thickness of the aluminium layer is between 0.02 and 1 mm. This thickness may be obtained using a single foil or two or more foils glued to each other with one of the methods described above. In such a case, the 'total thickness includes both the thickness of the aluminium foil and the thickness of the adhesive layers interposed between the foils.
According to a possible embodiment, the first layer has a first surface which is treated, for example by sanding, to obtain a suede effect. The first surface is the one opposite to the second layer. Examples of such processes described in one or more of the aforementioned patents are iricorporated herein by reference.
Lastly, the second layer can be moulded into a relatively firm shape in order to reproduce creasing and/or crinkling and/or wrinkling.
Advantageously, bonding a layer of non-woven microfibre fabric to a layer comprising- at least one sheet of aluminium foil makes it possible to : obtain structures with crinkled/creased or other surface effects which are relatively firm but ' which can be modified by the end user.
More specifically, the use of non-woven microfibre fabric comprising polyester or polyamide microfibres embedded in a polyurethane matrix makes it possible to obtain a composite product whose outside surface is very hard-wearing and has a particularly attractive appearance. The attractive appearance is enhanced by the fact that the outside surface of the layer of non-woven microfibre fabric can be treated, for example by sanding, to give it an effect similar to that of suede. A further advantage of this invention is the ease with which the. two layers, and where necessary, the sheets of aluminium foil, can be bonded together either using a customary adhesive or with one of the other methods described above.