[0001] This application claims priority from Australian provisional application 2021901046 and Australian provisional application 2021901045, both of which were filed on 09 April 2021 , the contents of which are entirely incorporated herein by this reference.

Technical Field

[0002] The invention relates to a fabric and a surface finish. More particularly, the present invention relates to the architecture and surface finishes of fabrics for use in impervious applications. It is to be appreciated that the present invention may be used in a wide variety of other applications, and aspects of the invention may be applicable to materials in addition to fabrics, or to enhance hydrophobicity or the hydrophilic properties of a fabric or material.

Background of Invention

[0003] The following discussion of background art is included to explain the context of the present invention. A reference herein to a matter which is given as prior art is not to be taken as an admission that the matter was known or that the information it contains was part of the common general knowledge as at the priority date of any of the claims.

[0004] Fabrics primarily come in two basic forms, woven and non-woven. They are formulated and manufactured in many different configurations and structures to attend to a wide range of purposes, such as clothing, shading, insulating, propelling (i.e. sails), load bearing structures, media/screen projections, advertising and surface covering.

[0005] Where fabrics are used in an outdoor/external environment, for example, as shade-cloth, or during a construction project, or as a surface or cover of outdoor furniture or building structures, they are made to be hydrophobic and resilient to external elements such as wind, sun/ultraviolet (UV) exposure and temperature variation. In addition to withstanding general environmental factors such as UV exposure, wind, rain, and temperature variations, fabrics can also be designed to withstand certain levels of tension, compression, torsion, or any load expected during normal use. For example, polytetrafluorethylene (PTFE) (a commonly known brand name of PTFE-based formulas is Teflon™) coated fabrics have been used in the roofing of sports stadiums such as the Wanda Metropolitano stadium in Madrid, and the new Optus™ stadium in Perth, Western Australia.

[0006] In certain outdoor structures and instalments in which a fabric is a key component, the fabric may comprise a polyester scrim, a Polyvinyl Chloride (PVC) coating and a PTFE treatment. These, and similar fabric compounds are particularly hydrophobic and repellent to dirt, predominantly due to the properties of PTFE.

[0007] PTFE is a synthetic fluoropolymer that has numerous applications and advantages when applied as a surface coating. It is commonly used as a coating of cookware, and to provide a ‘non-stick’ surface. PTFE is able to maintain its structural integrity under extreme temperature and is relatively resistant to chemical solvents. It is touted as having an excellent service life, as it retains its properties over a long period of time.

[0008] Despite the advantages of PTFE, fabric compounds containing PTFE are relatively expensive to manufacture, and are susceptible to weakness at segment joints. Further, compound fabrics are difficult to recycle or re-purpose, and can be environmentally detrimental due to the ability of the compound to maintain its structure over a very long period of time. Further, the scratching or wearing of surface coatings such as PTFE coatings significantly reduces the hydrophobicity of fabrics or materials to which the coating has been applied. In this respect, the hydrophobic coatings prepared by conventional chemical coating methods have poor durability, as noted in Cai et al WCMNM 2017 Hydrophobicity of Pyramid Structures Fabricated by Micro Milling.

[0009] Cai et al along with other publications (for example Kamegawa, Takashi & Irikawa, Koichi & Yamashita, Hiromi. (2017). Multifunctional surface designed by nanocomposite coating of polytetrafluoroethylene and TΌ2 photocatalyst: Self cleaning and superhydrophobicity. Scientific Reports. 7. 10.1038/s41598-017 -14058- 9.) have found that certain fabric structures and surface configurations have increased hydrophobicity compared to generally flat and/or unaltered surfaces. However, the application of these structures to woven and non-woven fabrics is difficult due to the complexity involved in the application of such a structure. Certain application methods include micro-milling which can be costly, and time consuming. As a result, micro-milling is not feasible in the manufacture of a low-cost material. Rather, methods such as micro-milling seem to be more applicable to solid/rigid items such as tools.

[0010] It is desirable to provide a fabric which addresses the shortcomings of compound fabrics such as those containing PTFE, whilst also maintaining similar or improved properties. Further, it is desirable to provide a surface finish applicable to a fabric, or any other material that improves hydrophobicity and dirt repellence of the fabric or material.

Summary of Invention

[0011] According to a broad first aspect of the present invention, there is provided a method of applying a surface finish to a material surface comprising: applying a surface pattern to the material surface through the application of a compressive force on to the material surface from a die, wherein, a pre-existing pattern on the die is embossed into the material surface, permanently altering the shape of the material surface, and wherein the pattern applied by the die onto the material surface is a three-dimensional (3D) pattern, the 3D pattern comprising an x-axis, a y-axis and a z- axis, and an X-Y plane, an X-Z plane and a Y-Z plane, wherein the pattern comprises consistently arranged peaks and troughs relative to the surface level of the material before the application of a surface finish or relative to a base of the surface after the application of the surface finish.

[0012] In one aspect of the invention the material to which the surface finish is applied may undergo pre-heating or wetting to enhance the application of the 3D pattern onto the surface.

[0013] The die applying the pattern to the surface may be a press-die or may be a single roller. In an embodiment of the invention, the die may be an assembly comprising at least a first roller and an opposing surface between which a material passes, wherein the first roller and/or the opposing surface is patterned. The opposing surface may be a second roller shaped and arranged to complement the first roller to facilitate embossing of a pattern on to a surface of a material passing therebetween, by subjecting the material to a compressive force.

[0014] As will be discussed in the detailed description, the application of certain 3D surface patterns to a material surface have been found to improve the hydrophobicity of a material. The deployment of certain patterns results in a higher water contact angle in comparison to a contact angle on a generally flat material surface.

[0015] In an embodiment of the invention, the 3D pattern applied to the surface of a material comprises a plurality of polyhedrons substantially equidistantly spaced in at least one axis and/or tessellated in at least one axis. The polyhedrons may be substantially identical pyramidal-like structures, protruding outwardly or recessed inwards relative to the material surface level before the application of the surface finish. The polyhedron structures may be substantially equidistantly spaced apart along at least one plane of the 3D axis. In alternative embodiments, the 3D pattern may comprise of structures resembling reuleaux pyramids, or frustoconical conical cylinders, cones, cubes, prisms (square, rectangular, triangular, circular, cylindrical) or any 3D shape whether it be a smooth edge or sharp edged, or a combination thereof.

[0016] The pyramidal-like structures of the above embodiment may comprise a top distance (TD), a pattern space (PS), a top width (TW), a height (H), and a length (L). The top distance is defined as being the shortest distance between two top-most points of two adjacent pyramidal-like structures when viewed in a 2-dimensional plane. The pattern space is defined as the shortest distance between two bottom most points of two adjacent pyramidal-like structures when viewed in the 2- dimensional plane. The top width is defined as a width of the top most section of a pyramidal-like structure when viewed in the 2-dimensional plane (for example consider a truncated triangle). The height is defined as the right-angle distance between a base and a peak of a pyramidal-like structure when viewed in a 2- dimensional plane. The length is defined as the external perimeter between the base and the peak of a pyramidal-like structure. [0017] Varying dimensions of the top distance, a pattern space, a top width, a height, and a length result in different degrees of hydrophobicity. In certain embodiments of the invention, the top distance may be between approximately 52.7 pm and approximately 308.6 pm; the pattern space may be between approximately

16.3 pm and approximately 170.6 pm, the top width may be between approximately

24.3 pm and approximately 217.3 pm, the height may be between approximately 18.1 pm and approximately 104.9 pm; and the length may be between approximately 25.3 pm and approximately 172.4 pm. The Applicant has found that pattern dimensions that fall within these ranges when applied to certain materials such as polypropylene, may result in surface water contact angles above 90°.

[0018] In further specific but not limiting embodiments of the invention, the top distance is approximately 124.2 + approximately 7.7 pm; the pattern space is approximately 29.9 + approximately 3.4 pm; the top width is approximately 45.7 + approximately 4.4 pm; the height is approximately 53.7 + approximately 2.3 pm; and the length is approximately 73.5 + approximately 4.9pm. The Applicant has found that a surface finish on a polypropylene substrate having pyramid-like structures falling within the ranges of these dimensions to have a relatively higher surface water contact angles, specifically in the range of 109.2+2.1°, resulting in significantly improved hydrophobicity. In comparison, the average surface water contact angle of an unaltered polypropylene material was found to be less than 30°, making the material somewhat hydrophilic.

[0019] Alternative 3D structures may be applied to a material surface, and in an alternative embodiment to the pyramid like structures, the pattern may be a hexagonal tessellation. The hexagonal structures may be embossed into the material in two modes. The structures may protrude outwards relative to a base material surface level obtained after the application of the surface finish. Alternatively, the hexagonal structures may be recessed inwards relative to the material surface level before the application of the surface finish.

[0020] A hexagonal tessellation applied to a material surface, such as a polypropylene substrate has been found to increase the hydrophobicity. The hydrophobic effectiveness of the hexagonal structures is dependent on a number of factors, primarily the dimensions of the structures. The dimensions may be categorised as follows: top distance (Hex-TD), pattern space (Hex-PS), top width (Hex-TW), height (Hex-H), and length (Hex-L).

[0021] The Hex-Pattern Space is defined as the diameter of a circumscribed circle of a base of a single hexagonal structure of the hexagonal tessellation. The Hex-Top Width is defined as the width of a peak section of a wall of a single hexagonal structure viewed in a 2-dimensional plane. The HEX-Height is defined as the generally perpendicular distance between the base and the peak section of a wall of a single hexagonal structure viewed in the 2-dimensional plane. The HEX-Length is defined as the external perimeter between the base and the peak of a single hexagonal structure viewed in the 2-dimensional plane.

[0022] According to the embodiment of the recessed hexagonal tessellation pattern, the HEX-Pattern Space may be approximately 345 + approximately 6.2 pm; the HEX-Top Width is approximately 24.3 + approximately 9.5 pm; the HEX-Height may be approximately 77.7+ approximately 4.1 pm; and the length may be approximately 141.6+ approximately 2.6 pm. The application of a recessed hexagonal pattern onto a polypropylene substrate, having the above dimensions, has been found to result in increased hydrophobicity of the substrate.

[0023] According to a second broad aspect of the invention, there is provided a surface finish applied to a material surface through the application of pressure onto the material surface from a die, wherein the surface finish comprises a 3D pattern of consistently arranged peaks and troughs, and wherein the 3D pattern comprises an x- axis, a y-axis and a z-axis, an X-Y plane, an X-Z plane and a Y-Z plane. Said surface finish may be applied according to any one of the method embodiments of first aspect of the invention noted above, or according to any feasible alternative method. The surface finish may comprise any one of the 3D patterns, configurations and dimensions noted in any of the above embodiments; or may comprise different patterns or dimensions which may produce favourable hydrophobic outcomes.

[0024] The material to which the surface finish of the above embodiments may be applied to can vary widely, form a metallic substance such as a metallic sheet, or a fabric. In a particular embodiment, the material may be a fabric, and specifically a homogenous multifilament and multi-strain polypropylene fibre fabric as described in the following paragraphs. The fabrics or materials to which the surface finish is applied can be utilised in any number of ways. For example, the fabrics or materials may be used to cover grain (grain covers), to cover water (water covers), to cover vehicles or objects, to provide shade (shade cloth), to cover construction sites, to cover roofing, or to cover scaffold. The fabric or material to which the surface is applied may be a product surface, for example, a vehicle surface, an internal or external surface of an item of clothing such as a shirt or shoe, a bottle surface, a tool or utensil surface, a cooking pot surface, or an electronic device surface such as that of a phone, tablet or computer or associated component. The surface finish is applicable to a non-exhaustive number of fabrics and materials for use in a wide variety of industries and environments.

[0025] According to a third broad aspect of the invention, there is provided a multifilament and multi-strain polypropylene fibre fabric comprising: a base layer having a first side and a second side, the base layer comprising a woven base fabric, a first layer in contact with and directly adjacent to the first side of the base layer, a second layer provided over the first layer, and a surface layer provided over the second layer, wherein make up of each of the first, second and surface layers comprise a large proportion of a polypropylene copolymer. In an alternative embodiment, the base layer may comprise a non-woven base fabric. It may be knitted, or a film.

[0026] A fabric according to the above aspect is capable of possessing similar characteristics to a PTFE coated material, at a lower relative cost. As the fabric is predominantly polypropylene, it has the added advantage of being easier to recycle and re-purpose. Further, the predominantly polypropylene architecture of the fabric allows for a relatively higher layer adhesion.

[0027] According to an embodiment of the fabric, at least two layers may be comprised of different compositions. As the fabric is generally polypropylene, the compositions include substantial amounts of polypropylene copolymer. The ability to amend the composition of each layer allows a manufacturer to tailor the fabric to a specific work environment, or to provide the fabric with specific characteristics such as higher UV resistance. [0028] In different embodiments, the fabric may comprise any one of, or a combination of, the following compositions:

- Composition a) which may include: a low flexural modulus polypropylene co polymer (Flex mod dOOrmPa), approximately 70% (by weight and/or volume); a low-density polyethylene, approximately 10% (by weight and/or volume); a halogenated flame retardant, approximately 10% (by weight and/or volume); and additives including pigment and UV block, approximately 10% (by weight and/or volume).

- Composition b) which may include: a low flexural modulus polypropylene co polymer (Flex mod dOOmPa), approximately 15-55% (by weight and/or volume); a medium flexural modulus polypropylene co-polymer, approximately 20-60% (by weight and/or volume); a halogenated Flame Retardant, approximately 10-15% (by weight and/or volume); and additives, approximately 10% (by weight and/or volume).

- Composition c) which may include: a low flexural modulus polypropylene co polymer, approximately 15-50% (by weight and/or volume); a medium flexural modulus polypropylene co-polymer, approximately 25-60% (by weight and/or volume); a halogenated flame retardant, approximately 15% (by weight and/or volume); and additives, approximately 10%.

- Composition s) which may include: a medium flex modulus polypropylene co polymer, approximately 70% (by weight and/or volume); a halogenated flame retardant, approximately 10% (by weight and/or volume); and additives, approximately 20% (by weight and/or volume).

[0029] Compositions a, b, c and s are formulated to provide different characteristics. For example, composition a) may be formulated to provide increased strength, and composition b) may be formulated to provide higher fire resistance, and higher UV resistance. Any polypropylene based formulation may be used, and the invention is not limited to the formulations and proportions noted above. In an embodiment of the fabric, composition s) is applied as a surface layer. Composition s) has a higher flex modulus compared to compositions a) to c), making it more capable of withstanding general external environmental conditions. [0030] To achieve the same level of fabric performance on both the first and second sides of the base layer, in an embodiment, the layers applied to the first side of the base layer may be symmetrically applied to the second side of the base layer. Therefore, in a further embodiment, the fabric may comprise a total of seven layers. Three layers may be applied to a first side of the base layer, and another set of identical layers may be symmetrically applied to the second side of the base layer. Alternatively, in certain embodiments, the layers may not be symmetrically applied about both sides of the base layer.

[0031] According to a further embodiment of the fabric, the total cumulative thickness of a first layer, a second layer and a surface layer applied to the first side of the base layer is approximately 110pm. In this embodiment, the first layer may have a maximum thickness of approximately 40pm, the second layer may have a maximum thickness of approximately 40pm, and the surface layer may have a maximum thickness of approximately 30pm. The same layers with the same thicknesses may also be applied to a second side of the base layer.

[0032] In a further embodiment, the fabric may comprise a total of six layers on a single side of the base layer, or six layers on each side of the base layer, giving the fabric a total of 13 layers. In this embodiment, a third layer may be provided over the second layer, a fourth layer may be provided over a third layer, a fifth layer may be provided over a fourth layer, and a surface layer may be provided over the fifth layer. In this embodiment, the cumulative maximum thickness of the first, second, third, fourth, fifth and surface layers may be adjusted as required and, in a particular embodiment, it may be approximately 250pm, and within the range of approximately 180-300 pm.

[0033] The fabric according to the further embodiment of paragraph [0031] comprising at least six layers on one side of the base layer has been found to provide numerous advantages over existing polypropylene fabrics. These advantages include, improved tear resistance, improved colour consistency, improved fire resistance, consistent surface finish and improved UV durability.

[0034] According to the further embodiment of paragraph [0031] whereby the cumulative maximum thickness of the first, second, third, fourth, fifth and surface layers is approximately 250 pm, and within the range of approximately 180-300 pm, the first layer may have a thickness of approximately 40-60pm, the second layer may have a thickness of approximately 40-60pm, the third layer may have a thickness of approximately 10-30 pm, the fourth layer may have a thickness of approximately 40- 60 pm, the fifth layer may have a thickness of approximately 40-60 pm and the surface layer may have a thickness of approximately 180-300 pm. These dimensions may be adjusted as required, so as to enhance certain characteristics.

[0035] The base layer of the fabric may be of any suitable polypropylene base scrim. In a particular embodiment, the base layer may be a homopolymer polypropylene, UV stabilized with hindered amine light stabilizer (HALS) - active % between approximately 0.4 and 1.0%, and comprises approximately 120 to approximately 180 multi-filaments per fibre, with a yarn denier of approximately 1000D to approximately 2000D, a base weave of approximately 7x7 yarns/cm (approximately 17.5/17.5 yarns/inch), and a fabric weight of approximately 205 to approximately 350 grams per sq meter (gsm). The base layer may be pigmented with carbon black having an active loading of approximately 1% to approximately 2% to absorb UV radiation making it more resistant to degradation. The yarn denier may be approximately 1300D, or approximately 1500D, or approximately 2000D. The base layer may further comprise approximately 144 multi-filaments per fibre.

[0036] To improve hydrophobicity, the fabric may comprise a surface finish according to the first and second aspects of the invention described above, and any of their associated embodiments. In addition to possessing the advantages noted in paragraph [0030] and [0032], a higher hydrophobicity may also give the fabric a ‘self cleaning’ effect, whereby water does not bead strongly with the fabric, and continuously slips off, taking with it any dirt or foreign particles that may have adhered to the fabric surface.

[0037] A fourth broad aspect of the invention provides a method of manufacturing a fabric according to the third broad aspect and any of its associated embodiments discussed above. The method comprises, passing the base layer through an extrusion coating assembly wherein a layer formulation in molten resin form is fed into a die slot and extruded as a single-piece material, which is then adhered to the first side of the base layer to form a single piece fabric. [0038] According to an embodiment of the fourth aspect of the invention, when the first layer formulation is forced through the die slot, additional layer formulations in molten resin form are concurrently fed into corresponding additional slots of the die. The molten layer formulations are then extruded into a multi-layered material, wherein the multi-layered material is adhered to the first side of the base layer.

[0039] In one particular embodiment, layer formulations corresponding to any one of composition a), and/or b), and/or c), and/or s), or any other composition, may form part of the extrusion coating process in which a multi-layer single piece material is extruded and adhered to the base layer.

[0040] To apply layers to the second side of the base layer, the single piece fabric resulting from the first pass through the coating assembly, is passed through the extrusion coating assembly a second time. A single layer formulation or a plurality of molten resin layer formulations is/are forced through corresponding slots of the die and extruded into a single-piece material. Each layer of the single-piece material will correspond to a single layer formulation fed through the die. The extruded single material is then adhered to the second side of the base layer of the single piece fabric, resulting in a new and thicker single piece fabric.

[0041] Each cycle of the extrusion coating assembly can be adjusted to extrude a single material comprising any number of layers. For example, each cycle may result in the creation of a single material comprising three layers, or four layers, or five layers, or six layers.

[0042] In an embodiment, the method of the fourth aspect may comprise an even number of passes through the extrusion coating process, wherein a resulting layer profile on the first side of the base layer of the single piece fabric is symmetrical to a layer profile on the second side of the base layer of the single piece fabric. In a further embodiment, the method may comprise two or four passes through the extrusion coating process.

[0043] In an embodiment, each pass of the base layer, or the single piece fabric through the extrusion coating assembly may result in the formation of a single piece material comprising three layers, which are then adhered to the base layer or, the single piece fabric. Therefore, in an embodiment of the fabric comprising a total of seven layers, the base will undergo a first pass, and the subsequently formed single piece fabric will undergo a second passes.

[0044] In the embodiment of the fabric comprising 13 layers, a total of four passes through the extrusion coating assembly will have occurred.

[0045] In the two embodiments of paragraphs [0042] and [0043], the final fabric may comprise seven or thirteen layers in total, whereby each side of the base layer is subjected to an equal number of passes (i.e one or two passes). In these embodiments, the molten resin layers applied in the extrusion coating assembly may be applied symmetrically. As previously noted, the application of the layers to the first and second side of the base layer does not need to be symmetrical. However, a symmetrical application of the layers to either side of the base layer can allow for the fabrication of a balanced and versatile fabric.

[0046] In an alternative embodiment, the method of the fourth aspect of the invention may comprise the adhesion of two extruded single-piece materials to the first and second side of the base layer simultaneously. In this embodiment, a single pass of the extrusion coating assembly may be result in the creation and two single piece materials for adhesion to the first and second side of the base. This would significantly reduce the manufacturing time of a single piece fabric requiring coatings on both the first and second side of the base layer.

[0047] The fourth aspect of the invention may include a further step, in which a surface finish may be applied to the fabric in accordance with the first and second aspects of the invention and any of their embodiments. The application of the surface finish may occur during the adhesion process of the single piece material to the base layer after a first or second pass through the extrusion coating process.

[0048] The application of the surface finish may also be performed during the adhesion process of the extruded material to a single-piece fabric during a third or subsequent pass through the extrusion coating process.

[0049] The application of such a surface finish will allow the fabric to be more water repellent, and self-cleaning, in addition to having a higher tear strength, improved colour consistency, improved fire resistance, more consistent surface finish and improved UV durability, and being more environmentally friendly. In this respect, a fabric that possess similar characteristics to those coated with PTFE may be produced at a lower financial and environmental cost.

[0050] Where the terms “comprise, “comprises”, “comprised” or “comprising” are used in this specification (including the claims) they are to be interpreted as specifying the presence of the stated features, integers, steps or components, but not precluding the presence of one or more other features, integers, steps or components, or group thereto.

Brief Description of Drawings [0051] Figures 1 and 16 - show parameters used to categorise surface finish patterns shown in the surface finishes of Figures 2 to 15, in a 2-dimensional plane.

[0052] Figures 2 shows a 3D model and a corresponding top perspective view of a surface finish having a hydrophilic surface finish pattern;

[0053] Figures 3 to 15 show 3D models of surface finish having hydrophobic surface finish patterns and corresponding top perspectives of surface finish patterns;

[0054] Figure 16 shows the key distinguishing parameters of recessed hexagonal patterns such as that utilised in Figure 15;

[0055] Figure 17 shows a cross-section of a 7-layer embodiment of a multifilament and multi-strain polypropylene fibre fabric; [0056] Figure 18 shows a cross-section of a 7-layer embodiment of a multifilament and multi-strain polypropylene fibre fabric.

Detailed Description

[0057] Referring to Figures 2 to 15, there is shown a plurality of surface finishes which can be applied to a material surface. The surface finishes shown in Figures 2 to 15 comprise 3D patterns. The surface finish patterns shown in Figures 3 to 15 when applied to a polypropylene fabric, have resulted in an increase in the water- contact angle with the fabric surface, relative to an untreated surface finish. The increase in the water contact angle with a material surface enhances the hydrophobicity of the surface, thus making the surface more water repellent, and self-cleaning, to varying extents. The surface finishes of the present invention, such as those shown in Figures 3 to 15 are applicable to a wide variety of materials to improve hydrophobicity. The surface finishes can be applied to any material surface that is malleable and deformable, such as for example, polypropylene fabric surfaces, polymer-based surfaces, plastics, plastic composites, compound surfaces, cements, bitumen, concrete, metallic surfaces or alloys.

[0058] It is to be appreciated that the surface finish of the present invention is not limited to the 3D patterns shown in Figures 2 to 15. Further, the surface finish of the present invention, such as those of Figures 2 to 15 are applied to a material surface by applying pressure on a patterned die such that the die exerts a compressive force on the material. As can be seen in Figures 2 to 15, the surface finish comprises a 3-D pattern of consistently arranged peaks and troughs, thus converting what was previously a generally flat 2-D surface into a 3-D patterned surface. The newly created 3-D surface comprises an X-axis 6, a Y-axis 8, and a Z-axis 10 as shown in Figure 2. As a result, the surface finish of the present invention comprises an X-Y plane, an X-Z plane and a Y-Z plane.

[0059] Surface finishes designed to increase hydrophobicity are designed to provide a generally consistent topography to allow for a water bead to form. With this in mind, the surface finishes of Figures 2 to 15 are designed to be patterned polyhedrons equidistantly spaced in at least one axis and/or tessellated in at least one axis. Figures 2 to 14 depict patterned surface finishes having a plurality of substantially identical structures, which generally resemble a truncated pyramid-type structure 12. The generally pyramidal structures 12 protrude outwardly from a base of a material surface 14; and are substantially equidistantly spaced apart along the X-Y plane. In alternative embodiments not shown in the drawings, the 3D patterns of the surface finish may comprise of structures resembling reuleaux pyramids, or frustoconical conical cylinders, cones, cubes, prims or any 3D shape whether it be a smooth edge or sharp edged, or a combination thereof. Further, a combination of substructures within larger structures may be included, for example, a small pyramidal like structure may be present between two larger truncated cone structures. [0060] In Figure 15, there is depicted tessellated hexagonal structures 16, recessed inwards, relative to the material surface before the application of the surface finish. The generally hexagonal structures 16 are substantially equidistantly spaced apart along the X-Y plane.

[0061] In alternative embodiments not shown in the drawings, the pyramidal structures 12 may be recessed inwards, relative to the surface level of the material before the surface finish is applied. Further, the hexagonal structures 16 may protrude outwardly from a base of the material surface.

[0062] The surface finish patterns of Figures 2 to 14 each comprise pyramidal structures of varying dimensions and spacing. Figure 1 illustrates the key parameters used to distinguish these patterns. The parameters are, a top distance 1 being the shortest distance between two top-most points of two adjacent pyramidal-like structures when viewed in a 2-dimensional plane; a pattern space 2, being a shortest distance between two bottom-most points of two adjacent pyramid-like structures when viewed in a 2-dimensional plane X-Y plane; a top width 3 being a width of the top most section of a pyramid-like structures when viewed in the 2-dimensional plane X-Y plane; a height 4, being the generally perpendicular distance between a base and a peak of a pyramid-like structures when viewed in a 2-dimensional X-Z or Y-Z plane; and a length 5 being an external diagonal perimeter between the base and the peak of a pyramid-like structures.

[0063] Figure 16 shows the key distinguishing parameters of recessed hexagonal patterns such as that utilised in Figure 15. These are: a pattern space 17, being a diameter of a circumscribed circle of a base of a single hexagonal structure 16 of the hexagonal tessellation; a top width 18 being a width of a peak section of a wall of a single hexagonal structure viewed in a 2-dimensional X-Y plane; a height 22, being the right-angle distance between the base and the peak section of a wall of a single hexagonal structure viewed in the 2-dimensional plane X-Z or Y-Z plane; and a length 24 being an external perimeter between the base and the peak of a single hexagonal structure viewed in the 2-dimensional plane.

[0064] The surface finish patterns shown in Figures 2 to 15 have been enlarged and are to scale. The grid lines 26 in Figures 2 to 15 running along the x-axis 6 and the y-axis 8 (i.e. within the X-Y plane) indicate increments of approximately 321pm from the intersection 28 of the X-Y-Z axis. The grid lines extending along the Y-axis 8 and the Z-axis 10 (i.e. the Y-Z plane) indicate increments of approximately 30 pm from the intersection 28 of the X-Y-Z axis.

[0065] The surface finish patterns shown in Figures 2 to 14 have dimensions that fall within the following ranges: a top distance 1 between approximately 52.7 + 3.7pm and approximately 411.8 +9.5 pm; a pattern space 2 between approximately 16.3 +3.5 pm and approximately 170.6 +1.8 pm; a top width 3 between approximately 24.3 + 9.5 pm and approximately 218.3+1.0 pm; a height 4 between approximately 18.1 + 1.4 pm and approximately 104.9 + 1.0pm; and a length 5 between approximately 25.3 + 3.7 pm and approximately 172.4 + 7.1 pm.

[0066] In Figure 2, there is a surface finish pattern 30 (also referred to as 45 Q in table 1 below), comprising a plurality of pyramidal structures 31 which have a relatively larger top distance compared to the surface finish patterns of Figures 3 to 15. The surface finish pattern 30 comprises the following dimensions: a top distance 1 of approximately 411.8±9.5 pm; a pattern space 2 of approximately 150.3±5.9 pm, a top width 3 of approximately 97.7±1.7 pm, a height of approximately 97.7+ 1.7 pm and a length 5 of approximately 172.4±7.1 pm. Surface finish pattern 30, when applied to a polypropylene fabric was found to be highly hydrophilic. Such hydrophilic properties are desirable in materials commonly used in water-transfer type applications.

[0067] In Figure 3, there is a surface finish pattern 32 (also referred to as 65 Q in table 1 below), comprises a relatively denser pyramidal structure 33 pattern to that of the Figure 2 surface finish 30. The surface finish pattern 32 comprises the following dimensions: a top distance 1 of approximately 308.6±16.9 pm; a pattern space 2 of approximately 122.5±4.2 pm, a top width 3 of approximately 98.9±12.0 pm, a height of approximately 80.8±7.3 pm and a length 5 of approximately 122.4±9.9 pm. Surface finish pattern 32, when applied to a polypropylene fabric was found to be hydrophobic, with an average water contact angle of over 100°.

[0068] In Figure 4, there is a surface finish pattern 34 (also referred to as 65 Q matte in table 1 below), which has a similar pyramidal structure density 35 to that of pattern 32 of Figure 3. The pyramidal structures 35 of the pattern 34 appear to higher and narrower than those of Figure 3. The surface finish pattern 34 comprises the following dimensions: a top distance 1 of approximately 272.5±13.4 pm; a pattern space 2 of approximately 91.3±14.0 pm, a top width 3 of approximately 114.4±16.7 pm, a height of approximately 89.1 ±11.0 pm and a length 5 of approximately 139.4±13.7 pm. Surface finish pattern 34, when applied to a polypropylene fabric was found to be more hydrophobic than that of Figure 3, with an average water contact angle of over 100°.

[0069] In Figure 5, there is a surface finish pattern 36 (also referred to as 65 SQ deep in table 1 below), which has a similar pyramidal structure 37 density to that of patterns 32 and 34. The pyramidal structures 37 of the pattern 36 appear to have a larger top width 3, height 4, and length 5, to those of Figure 3 and 4. The surface finish pattern 36 comprises the following dimensions: a top distance 1 of approximately 301.9±2.4 pm; a pattern space 2 of approximately 90.3±17.0 pm, a top width 3 of approximately 218.3±1.0 pm, a height of approximately 104.9 pm and a length 5 of approximately 164.7+11.4 pm. Surface finish pattern 36, when applied to a polypropylene fabric was found to be less hydrophobic than that of Figures 3 and 4, with an average water contact angle of approximately 90°.

[0070] In Figure 6, there is a surface finish pattern 38 (also referred to as 95 Q in table 1 below), which has a more dense pyramidal structure 39 pattern compared to that of patterns 32 and 34. The pyramidal structures 39 of the pattern 38 have a smaller top distancel , pattern space 2, height 4, and length 5, to those of Figure 3, 4 and 5. The surface finish pattern 38 comprises the following dimensions: a top distance 1 of approximately 151.3±9.6 pm; a pattern space 2 of approximately 60.2±2.6 pm, a top width 3 of approximately 110.7±3.8 pm, a height of approximately 43.0±3.7 pm and a length 5 of approximately 66.7±2.9 pm. Surface finish pattern 38, when applied to a polypropylene fabric was found to have an average water contact angle of approximately 99°, which is slightly lower than the contact angles of surface finish patterns 32, and 34.

[0071] In Figure 7, there is a surface finish pattern 40 (also referred to as 120 Q in table 1 below), which has a denser pyramidal structure 41 pattern to that of patterns 38. The pyramidal structures 41 of the pattern 40 have a significantly smaller top width 3 to those of Figure 6. The surface finish pattern 40 comprises the following dimensions: a top distance 1 of approximately 146.5±8.2 pm; a pattern space 2 of approximately 49.9±4.2 pm, a top width 3 of approximately 66.0±7.6pm, a height of approximately 49.2±3.0pm and a length 5 of approximately 65.3±4.8 pm. Surface finish pattern 40, when applied to a polypropylene fabric was found to have an average water contact angle of approximately 102°.

[0072] In Figure 8, there is a surface finish pattern 42 (also referred to as X-120-X in table 1 below), which has a similar density of pyramidal structures 43 to that of patterns 40. Flowever, the pyramidal structures 43 of pattern 42 are generally narrower than those of pattern 40. The surface finish pattern 40 comprises the following dimensions: a top distance 1 of approximately 167.1 ±4.2 pm; a pattern space 2 of approximately 80.3±5.2 pm, a top width 3 of approximately 46.2±5.7 pm, a height of approximately 55.3±4.8 pm and a length 5 of approximately 75.1 ±6.4 pm. When applied to a polypropylene fabric, surface finish pattern 42 was found to have an average water contact angle of approximately 103.5°.

[0073] In Figure 9, there is a surface finish pattern 44 (also referred to as 150 Q in table 1 below), which has a higher density of pyramidal structures 45 to that of pattern 42. The surface finish pattern 44 comprises the following dimensions: a top distance 1 of approximately 124.2±7.7 pm; a pattern space 2 of approximately 29.9±3.4 pm, a top width 3 of approximately 45.7±4.4 pm, a height of approximately 53.7±2.3 pm and a length 5 of approximately 73.5±4.9 pm. When applied to a polypropylene fabric, surface finish pattern 44 was found to have an average water contact angle of approximately 109°, which is the highest of the surface finishes of shown in Figures 2 to 15.

[0074] In Figure 10, there is a surface finish pattern 46 (also referred to as 180 Q in table 1 below), which has a higher density of pyramidal structures 47 to that of pattern 44, but with generally smaller pyramidal structures 47. The surface finish pattern 46 comprises the following dimensions: a top distance 1 of approximately 103.4±2.6 pm; a pattern space 2 of approximately 36.1 ±2.7 pm, a top width 3 of approximately 40.9±2.0 pm, a height of approximately 24.3±2.4 pm and a length 5 of approximately 45.3±6.3 pm. When applied to a polypropylene fabric, surface finish pattern 46 was found to have an average water contact angle of approximately 103°. [0075] In Figure 11 , there is a surface finish pattern 48 (also referred to as 180 Z in table 1 below), which has a similar density of pyramidal structures 49 to that of pattern 46, but with generally smaller pyramidal structures 49. The surface finish pattern 48 comprises the following dimensions: a top distance 1 of approximately 110.9±4.6 pm; a pattern space 2 of approximately 54.7±2.0 pm, a top width 3 of approximately 34.1±2.0 pm, a height of approximately 25.2±1.7 pm and a length 5 of approximately 39.3±4.4 pm. When applied to a polypropylene fabric, surface finish pattern 48 was found to have an average water contact angle of approximately 93°.

[0076] In Figure 12, there is a surface finish pattern 50 (also referred to as 200 CFIQ in table 1 below), which has a higher density of pyramidal structures 51 to that of patterns 46 and 48, but with generally smaller pyramidal structures 51. The surface finish pattern 50 comprises the following dimensions: a top distance 1 of approximately 88.6±4.8 pm; a pattern space 2 of approximately 51.9±2.8 pm, a top width 3 of approximately 39.4±2.8 pm, a height of approximately 19.4±1.3 pm and a length 5 of approximately 29.8±3.5 pm. When applied to a polypropylene fabric, surface finish pattern 50 was found to have an average water contact angle of approximately 101.5°.

[0077] In Figure 13, there is a surface finish pattern 52 (also referred to as 300 CFIQ in table 1 below), which has a higher density of pyramidal structures 53 to that of pattern 50, and generally smaller pyramidal structures 53. The surface finish pattern 52 comprises the following dimensions: a top distance 1 of approximately 52.7±3.7 pm; a pattern space 2 of approximately 16.3±3.5 pm, a top width 3 of approximately 28.6±4.5 pm, a height of approximately 18.1 ±1.4 pm and a length 5 of approximately 25.3±3.7 pm. When applied to a polypropylene fabric, surface finish pattern 52 was found to have an average water contact angle of approximately 74°.

[0078] In Figure 14, there is a surface finish pattern 54 (also referred to as 505 CFIQ in table 1 below) which has a similar density of pyramidal structures 55 to that of pattern 30 in Figure 2. The pyramidal structures 55 are generally smaller than those of pattern 30. The surface finish pattern 54 comprises the following dimensions: a top distance 1 of approximately 294.8±7.2 pm; a pattern space 2 of approximately 170.6±1.8 pm, a top width 3 of approximately 218.0±1.0 pm, a height of approximately 54.1 ±3.9 pm and a length 5 of approximately 83.4±9.4pm. When applied to a polypropylene fabric, surface finish pattern 54 was found to have an average water contact angle of approximately 100°.

[0079] In Figure 14, there is a surface finish pattern 56 (also referred to as 40HEX in table 1 below. The pattern 56 comprises a plurality of tessellated hexagonal structures 57, recessed inwards relative to an unaltered surface. The surface finish pattern 57 comprises the following dimensions: a pattern space 18 of approximately 345.9±6.2 pm, a top width 20 of approximately 24.3±9.5 pm, a height 22 of approximately 77.7±4.1 pm and a length 24 of approximately 141.6±2.6 pm. When applied to a polypropylene fabric, surface finish pattern 56 was found to have an average water contact angle of approximately 89.7°.

[0080] During laboratory testing of the surface finishes of Figures 2 to 15, the polypropylene fabric samples were coated with a 3 nm thick gold layer using a BAL- TEC SCD 050 sputter coater (Leica Microsystems, Australia) to avoid surface charge during imaging. The morphology of the produced fabrics/samples was examined by Scanning Electron Microscopy (SEM) on a JEOL 7800F (JEOL, Tokyo, Japan). The accelerating voltage was set to 5 kV for a working distance of 10 mm.

[0081] Top perspective Images shown in Figures 2 to 15 were taken using 10x optical lens across an area of 1284 ^c 1284 pm2 and 1024 x 1024 pixels. The critical dimensions, of each surface finish depicted in Figures 3 to 15 were measured using a LEXT OLS4100 3D Measuring Laser The images were taken using 10x optical lens across an area of 1284 ^c 1284 pm2 and 1024 ^c 1024 pixels.

[0082] The water contact angle formed at the interface between the surface of the fabric samples and liquid water droplets was measured using water contact angle instrument with 4 pL of water model (KSV instrument made CAM 101). Five measurements were conducted and averaged.

[0083] The results obtained for each of the surface finish patterns shown in Figures 2 to 15 were compared to those obtained against a control sample. The control sample is not shown in the Figures. The control sample comprises a relatively flat 2-dimensional surface. It was found that the surface finish patterns of Figures 3 to 15 resulted in a significant increase in hydrophobicity. The surface finish pattern 30 of Figure 2 resulted in an increase in the hydrophilic potential of the material. The table below provides a summary of the results of the testing, along with a breakdown of the key dimensions of each surface finish pattern of Figures 2 to 15.

[0084] Table 1

[0085] Surface finishes designed to increase hydrophobicity generally provide a consistent topography to allow for a water bead to form. As can be seen in the results in Table 1 , no single pattern dimension is determinative of hydrophobicity. Rather, the combination of dimensions used in the surface finish 44 of Figure 9 was found to have the highest water contact angle of 109.2+2.1°. The pyramidal structures 43 of Figure 9 comprises the following dimensions: a top distance 1 of approximately 124.2 + approximately 7.7 pm; a pattern space 2 of approximately 29.9 + approximately 3.4 pm; a top width 3 of approximately 45.7 + approximately 4.4 pm; a height of approximately 53.7 + approximately 2.3 pm; and a length of approximately 73.5 + approximately 4.9pm. The dimensions of the surface finish 44 were found to provide optimal hydrophobicity during testing. However, it is to be appreciated that additional amendments and variations to the dimensions may be applied to further optimise the hydrophobic properties, or hydrophilic properties, of the surface finish patterns 30 32, 34, 36, 38, 40, 42, 44, 46, 48, 50, 52, 54, 56.

[0086] Although not shown in the drawings, a particular variation to improve the hydrophobic or hydrophilic properties involves the application of sub-pyramidal structures or other type of sub structures along the pattern space 2 section, or within the hexagonal pattern space 18.

[0087] To apply the surface finish patterns (30 32, 34, 36, 38, 40, 42, 44, 46, 48, 50, 52, 54, 56) of Figures 2 to 15 to a material surface, a pre-existing pattern on a die is embossed into the material surface, through the application of pressure of the die on to the material surface. That is, the material surface is compressed by the die and is permanently altered/deformed to mimic the pattern on the die. Although not shown in the Figures, the die may be an assembly comprising at least a first roller and an opposing surface such as a flat panel, between which a material passes. The first roller and/or the opposing surface may be patterned. Alternatively, the die assembly may comprise of at least a second roller in place of the flat panel. In this case, the material to which the surface finish is to be applied will pass between two rollers, which apply a compressive pressure on to the material, embossing any patterns that may be present on either or both the rollers.

[0088] A material may be automatically passed through a die assembly, the speed of which may be controlled using variable speed drives, sensors and/or PLCs.

[0089] A material may be pre-heated, wetted, or have a chemical agent applied to it, to more effectively receive the surface finish applied through the die assembly. Such pre-treatment may act to temporarily soften the material, to make it more malleable, flexible, and less susceptible to tearing.

[0090] Where a material cannot be passed through a die assembly comprising a roller, a press-die may be used, or any other alternative embossing method may be used. [0091] Figures 17 and 18 show cross-sections 80, 82, 84 and 86 of four configurations of a multifilament and multi-strain polypropylene fibre fabric.

[0092] The cross-sections 80, 82, 84 and 86 all have a common base layer 88. The base layer 88 has a first side 90 and a second side 92. The base layer can be of any suitable polypropylene fabric. In a preferred embodiment, the base layer 88 is a homopolymer polypropylene, UV stabilized with hindered amine light stabilizer (HALS) - active % between approximately 0.4 and 1.0%. In this preferred embodiment the base layer 88 comprises approximately 120 to approximately 180 multi-filaments per fibre, with a yarn denier of approximately 1000D to approximately 2000D, a base weave of approximately 7x7 yarns/cm (approximately 17.5/17.5 yarns/inch), and a fabric weight of approximately 205 to approximately 350 grams per sq meter (gsm).

[0093] To enhance resilience against UV degradation, the base layer 88 is pigmented with carbon black. The carbon black may have an active loading of approximately 1% to approximately 2%, or higher depending on the UV exposure the end fabric will be subjected to.

[0094] The yarn denier of the base layer 88 can vary depending on the end purpose of the fabric, and in preferred multipurpose embodiments it is approximately 1300D, or approximately 1500D, or approximately 2000D. Similarly, the multi filaments per fibre can be varied across different embodiments of the base layer 88, and in preferred multipurpose embodiments the base layer 88 comprises approximately 144 multi-filaments per fibre.

[0095] Cross-section 80 of Figure 17 has a first layer 94 in contact with and directly adjacent to the first side 90 of the base layer 88. A second layer 96 is provided over the first layer 94. A surface layer 98 provided over the second layer 96. As the fabric of the present invention is a multifilament and multi-strain polypropylene fibre fabric, each layer 94, 96, and 98 is a polypropylene copolymer.

[0096] The composition of each layer 94, 96 and 98 may be identical, or they may vary. In a particular embodiment, the formulation/composition of each layer may be tailored to make the entire fabric homogenous. The compositions can be amended to provide the fabric with different properties such as enhanced tear strength, better colour consistency, and/or better UV resistance.

[0097] In a preferred embodiment, the composition of layers 94, 96 and 98 comprise the same or similar elements/ingredients, however, the proportions of these elements/ingredients may differ. For example, layer 94 is comprised of composition a) which includes: a low flexural modulus polypropylene co-polymer (Flex mod dOOrmPa), approximately 70% (by weight and/or volume); a low-density polyethylene, approximately 10% (by weight and/or volume); a halogenated flame retardant, approximately 10% (by weight and/or volume); and additives including pigment and UV block, approximately 10% (by weight and/or volume). The thickness of the first layer can vary, and in an embodiment, is applied with a maximum thickness of approximately 40pm. It is to be noted that the percentages used here relate to either both volume and/or weight, as the density to weight ratio of the properties noted above is close to 1.

[0098] Further, layer 96 is comprised of composition b) which includes: a low flexural modulus polypropylene co-polymer (Flex mod dOOrmPa), approximately 15- 55% (by weight and/or volume); a medium flexural modulus polypropylene co polymer, approximately 20-60% (by weight and/or volume); a halogenated Flame Retardant, approximately 10-15% (by weight and/or volume); and additives, approximately 10% (by weight and/or volume). The thickness of the second layer can vary, and in an embodiment, is applied with a maximum thickness of approximately 40pm. It is to be noted that the percentages used here relate to either both volume and/or weight, as the density to weight ration of the properties noted above is close to 1.

[0099] Further, surface layer 98 is comprised of composition s) which includes: a medium flex modulus polypropylene co-polymer, approximately 70% (by weight and/or volume); a halogenated flame retardant, approximately 10% (by weight and/or volume); and additives, approximately 20% (by weight and/or volume). The thickness of the surface layer 98 can vary, and in this embodiment, is applied with a maximum thickness of approximately 30pm. It is to be noted that the percentages used here relate to either both volume and/or weight, as the density to weight ration of the properties noted above is close to 1. [0100] To allow for versatility of use of the fabric, layers 94, 96 and 98 are applied symmetrically to the second side 92 of the base layer 88, as shown in cross-section 82 of Figure 17. However, this is not essential in situations where the second side 92 of the base layer is sheltered or protected from external elements, or other detrimental elements, or in scenarios or uses where there is no need to apply layers 94, 96 and 98 to the second side 92.

[0101] The embodiment of cross-section 82 comprises a total of six layers symmetrically distributed about the first 90 and second 92 sides of the base layer 88. The thickness of each layer can vary, and in a preferred embodiment the cumulative maximum thickness of the first layer 94, the second layer 96, and the surface layer 98 is approximately 110pm as applied to the first 90 or second side 92 of the base layer 88. As a result, the total thickness of applied layers 94, 96 and 98 to both sides of the base layer 88 is 220 pm.

[0102] To obtain a fabric with enhanced tear resistance, an additional three layers 100, 102, 104 are included. Embodiments of this enhanced fabric are shown in Figure 18, cross-sections 84 and 86. In cross-sections 84 and 86, a third layer 100 is provided over the second layer 96, a fourth layer 102 provided over the third layer 100, a fifth layer 106 is provided over a fourth layer 104, and the surface layer 98 provided over the fifth layer 106. The cross-section 84 shows the application of six layers 94, 96, 100, 102, 104 and 98 to the first side of the base layer. Cross-section 86 shows a symmetrical application of the six layers 94, 96, 100, 102, 104 and 98 to the second side of the base layer.

[0103] In the cross-sections of 84 and 86, the composition of the first layer 94 is that of composition a). The second 96, third 100, fourth 102 and fifth 104 layers are comprised of composition c) which includes: a low flexural modulus polypropylene co polymer, approximately 15-50%; a medium flexural modulus polypropylene co polymer, approximately 25-60%; a halogenated flame retardant, approximately 15%; and additives, approximately 10%. The surface layer 98 is that of composition s).

[0104] Cross-section 84 comprises a total of six layers (94. 96, 98, 100, 102, 104) in addition to the base layer 88. A fabric according to cross-section 84 is suitable for use where the base layer 88 is sheltered or protected from external elements, or other detrimental elements.

[0105] Cross-section 86 is designed to provide a versatile fabric, whereby each side of the fabric can be used for the same purpose. In total, cross-section 86 comprises 13 layers (having two applications of layers 94. 96, 98, 100, 102, 104 on either side 90, 92 of the base layer 88) inclusive of the base layer 88. The cumulative thickness of the six layers 94. 96, 98, 100, 102, 104, added to a side 90, 92 of the base is approximately 250pm, and can range between approximately 180-300 pm.

[0106] Specifically, the first layer has a thickness of approximately 40-60 pm, the second layer has a thickness of approximately 40-60 pm, the third layer has a thickness of approximately 10-30 pm, the fourth layer has a thickness of approximately 40-60 pm, the fifth layer has a thickness of approximately 40-60 pm and the surface layer has a thickness of approximately 10-20 pm.

[0107] The number, order, composition and thickness of the layers can be varied and does not need to strictly adhere to those shown in Figures 17 and 18 or described in this application. The embodiments shown in Figure 18, specifically cross- section 86, has been found to provide a relatively higher tear strength, improved colour consistency, improved fire resistance, more consistent surface finish and improved UV durability, relative to the embodiments shown in Figure 17 and other currently available polypropylene fabrics. Further, due to the polypropylene construction of the fabric, there exists high levels of coating adhesion. Further, the reliance on polypropylene as the predominant ingredient in the makeup of the fabric allows for the fabric to be manufactured relatively cheaper than other fabrics/materials possessing similar qualities. The makeup of the fabric also allows it to be more easily recyclable, and re-purposed.

[0108] To improve the hydrophobicity, or the hydrophilic properties of the fabric, a surface finish according to any one of those shown in Figures 2 to 15 may be applied to the surface layer 98 of the fabric.

[0109] Manufacturing the multi-layered fabric according to Figures 17 and 18 requires the base layer 88 to be initially passed through a coating assembly. The coating assembly can be a knife coating assembly, or preferably an extrusion coating assembly. Compositions a), or b), or c) or s) of layers 94, 96, 98, 100, 102 and 104 to be adhered to the scrim in the first pass, are concurrently fed through a series of separate die slots, in molten resin form. A single formulation or multiple formulations may be passed through a single die slot. In the embodiments of Figures 17 and 18, multiple formulations are fed through individual die slots and a single-piece material is extruded. Each layer of the single piece material corresponds to a single composition/formulation fed into individual die slots. The single-piece layer is then adhered to the first side 90 of the base layer 88. Layer 94 is to be adhered to the surface of the first side 90 of the base layer 88. The adhesion of the single-piece material and the base layer 88 results in the formation a single piece fabric.

[0110] To apply layers on to the second side 92 of the base layer 88, the single piece fabric is to go through a second pass through the extrusion coating assembly. Much like the first pass, the molten resin formulations/compositions of the layers are fed into individual die slots. A single-piece material is then extruded. Each layer of the single piece material again corresponds to a single composition/formulation fed into the individual die slot/s. The single-piece layer is then adhered to the second side 92 of the base layer 88. The adhesion of the newly generated single-piece material to the single-piece fabric results in the formation of a new and thicker single piece fabric.

[0111] Each cycle of the extrusion coating assembly can be adjusted to extrude a single material comprising any number of layers. For example, each cycle may result in the creation of a single material comprising three layers, or four layers, or five layers, or six layers. The order in which the layers appear in the single piece-material can be controlled and amended as required by adjusting flow formulation into designated slots. For example, if layer 98 is to be the first layer, the formulation of the layer will be fed into a first layer die slot. In this example, die slot number 1 may correspond to layer 1 , and die slot 2 may correspond to layer 2.

[0112] In the process used to fabricate the embodiments of Figures 17 and 18, each pass through the extrusion coating assembly resulted in the extrusion of a three layered single-piece material. In the first two passes, the layers of the extruded single piece material were identical in order and volume (i.e. are symmetrical in order and volume). In the third and fourth passes, the layers of the extruded single-piece material were identical in order and volume, (i.e. symmetrical in order and volume). The order of the layer formulation fed into the die between the first two passes and the second two passes can be amended as required by adjusting the die slot number the formulations are fed into.

[0113] In each pass of the extrusion coating process during the fabrication of the embodiments of Figures 17 and 18, three separate formulations/compositions were fed into the die. The resulting extruded material from each pass comprised three layers. The machinery used in the development of this invention limited the material to three separate layers, and the adhesion of only a single extruded material to only one side 90, 92 of the base layer. It is to be appreciated that the extrusion coating assembly can generate a single-piece material comprising more than three layers, provided the assembly has the required equipment and/or capacity.

[0114] In this respect, an even number of passes through the extrusion coating process can provide a symmetrical layer profile about the base layer 88, as is shown in cross-sections 82 and 86.

[0115] Two passes through the extrusion coating assembly were required to obtain a fabric with cross-sections 80 and 84 shown in Figures 17 and 18. As can be seen, cross sections 80 and 82 comprise 7 layers. Four passes through the extrusion coating assembly were required to obtain the 13 layer cross-section of 86 shown in Figure 18. In cross-section of 82 and 86, the fabric layers are arranged symmetrically about the base layer 88.

[0116] It is to be appreciated that the method of the present invention extends to an extrusion process capable of generating a single-piece material having more than three layers. Further the present invention also extends to an extrusion process capable of concurrently generating two or more single-piece materials having more any number of layers. In an alternative embodiment, two single-piece extrusions may be generated concurrently in a single pass, whereby the number of layers in each extrusion may be equal to or greater than one. The two single-piece layers may be identical, symmetrical or configured to be different. The adhesion of the two extruded single-piece materials to the first side 90 and second side 92 of the base layer 88 may also occur concurrently, or sequentially in a single pass. In this alternative embodiment, a single pass of the extrusion coating assembly results in the creation of two single-piece materials for adhesion to the first side 90 and second side 92 of the base 88 in a single pass. This significantly reduces the manufacturing time of a single piece fabric requiring coatings on both the first and second sides of the base layer.

[0117] A surface finish as shown in Figures 2 to 15, or any other surface finish according to embodiments of the invention not shown in the drawings can be applied during the fabric manufacturing process. The surface finish may be applied using the method described in paragraphs [0086] to [0089], and the application step may form part of the step in which the adhesion of the extruded single-piece material and the single-piece fabric occurs. This step involves the compression of the material and fabric using a chilled roller. In an embodiment, the chilled roller may also comprise an inverse surface finish pattern for the embossing of the surface onto a surface layer 98. The chilled roller in this instance also acts as a surface finish die which embosses a surface finish onto a freshly fabricated fabric.

[0118] An inverse surface pattern may be engraved onto the surface of the chilled roller, using a laser cutter/engraver. Alternatively, the pattern may be micro-milled into the roller surface or may be applied using any method applicable to achieving a pattern comprising structures at possessing dimensions at a pm level. When the surface layer 98 of the freshly adhered fabric meets the chilled roller, the compressive force exerted by the chilled roller onto the fabric results in the desired surface pattern being embossed onto surface layer 98.

[0119] It is to be understood that various alterations, modifications and/or additions may be introduced into the construction and arrangement of the parts previously described without departing from the spirit or ambit of this invention.

List of Reference Numerals

1 - Pyramidal pattern top distance

2 - Pyramidal pattern space

3 - Pyramidal structure top width

4 - Pyramidal structure height

5 - Pyramidal structure length

6 - X-axis 8 - Y- axis

10 - Z- axis

12 - Pyramid structure (shown in Figure 1 )

14 - Material surface

16 - Hexagonal structures

18 - Hexagonal pattern space

20- Hexagonal top width

22 - Hexagonal structure height

24 - Hexagonal length

26 - grid lines

28 - Axis Intersection point

30 - Surface finish 45Q

31 - 45Q Pyramidal structure/pattern

32 - Surface Finish 65 Q

33 - 45Q Pyramidal structure/pattern

34 - Surface finish 65 Q matte

35 - 65 Q matte Pyramidal structure/pattern

36 - Surface finish 65 SQ deep

37 - 65 SQ deep Pyramidal structure/pattern

38 - Surface finish 95 Q

39 - 95 Q Pyramidal structure/pattern

40 - Surface finish 120 Q

41 -120 Q Pyramidal structure/pattern

42 - Surface finish X-12-X

43 - X-12-X Pyramidal structure/pattern

44 - Surface finish 150 Q

45 - 150 Q Pyramidal structure/pattern 46 - Surface finish 180 Q

47 - 180 Q Pyramidal structure/pattern

48 - Surface finish 180 Z

49 - 180 Z Pyramidal structure/pattern 50 - Surface finish 200 CHQ

51 - 200 CHQ Pyramidal structure/pattern

52 - Surface finish 300 Q

53 - 300 CHQ Pyramidal structure/pattern

54 - Surface finish 505 Q shallow 55 - 505 Pyramidal structure/pattern

56 - Surface finish 40 HEX

57 - 40 HEX Hexagonal structure / pattern 80 - Cross-section of embodiment 1

82 - Cross-section of embodiment 2 84 - Cross-section of embodiment 3

86 - Cross-section of embodiment 4 88 - Base layer 90 - Base layer first side 92 - Base layer second side 94 - First layer

96 - Second layer 98 - Surface layer 100 - Third layer 102 - Fourth layer 104 - Fifth layer