Fabric-faced composites and methods for making same

Abstract

The present invention is directed to multiple layer composites ( 10 ) suitable for use as wall and floor coverings, among other uses, that provide a strong durable structure and a soft textile or fabric face. The composite includes a face layer ( 12 ) bonded to an adhesive layer ( 22 ) such that the adhesive layer ( 22 ) penetrates into the face layer ( 12 ). The face layer ( 12 ) can have legs ( 19, 34 ) extending there from, and such legs ( 19, 34 ) are anchored by the adhesive layer to provide stronger attachment between the adhesive layer and the face layer. A backing layer ( 26 ) may also be provided in contact with the adhesive layer ( 22 ) such that the adhesive layer also embeds into the backing layer ( 26 ), and the legs ( 19, 34 ) extending from the face layer may penetrate into the backing layer.

1 - 3 . (canceled)  
   
   
       4 . A composite comprising a fibrous face layer forming at least a portion of a top surface of the composite, wherein the face layer has a top surface and a bottom surface opposite the top surface, and wherein the fibrous face layer comprises a plurality of legs dependent from the fibrous face layer, and 
 an adhesive layer having a top surface that corresponds to the bottom surface of the fibrous face layer and is in direct contact with the bottom surface of the fibrous face layer, wherein the legs of the fibrous face layer are anchored in the adhesive layer, wherein the adhesive layer is stitch-bonded with yarns and wherein said yarns form the fibrous face layer comprising a plurality of yarn underlaps.    
   
   
       5 . The composite of  claim 4 , wherein said yarns form a fibrous bottom surface comprising a plurality of yarn overlaps and the adhesive layer is disposed between the fibrous face surface and the fibrous bottom surface.  
   
   
       6 . The composite of  claim 4 , wherein the adhesive layer comprises a thermoplastic film that is post-activated to anchor the legs in the adhesive layer.  
   
   
       7 . The composite of  claim 4 , wherein the face layer is substantially fully covered with yearn underlaps.  
   
   
       8 - 38 . (canceled)  
   
   
       39 . A method for making a composite, the method comprising: 
 selecting a fibrous face layer comprising a plurality of fibers, wherein the face layer has a top surface and a bottom surface opposite the top surface, and wherein the face layer comprises a plurality of legs dependent there from;    placing an adhesive layer in direct contact with the bottom surface of the fibrous face layer; and    embedding the legs of the fibrous face layer in the adhesive layer a distance sufficient to anchor the face layer in the adhesive layer.    
   
   
       40 . The method of  claim 39 , further comprising needle punching the face layer to produce the plurality of legs, the plurality of legs comprising a plurality of free fiber ends at the bottom surface.  
   
   
       41 . The method of  claim 39 , further comprising spunlacing the face layer to produce the plurality of legs, the plurality of legs comprising a plurality of free fiber ends at the bottom surface.  
   
   
       42 . The method of  claim 39 , wherein the step of embedding the adhesive layer comprises: 
 activating the adhesive layer; and    applying pressure to the top surface of the face layer.    
   
   
       43 . The method of  claim 39 , wherein the step of embedding the adhesive layer comprises needle punching the plurality of legs into the adhesive layer.  
   
   
       44 . The method of  claim 39 , further comprising placing a backing layer in direct contact with the adhesive layer such that the adhesive layer is disposed between the backing layer and the face layer and embedding the adhesive layer into the backing.  
   
   
       45 . The method of  claim 44 , wherein the step of embedding the adhesive layer comprises needle punching the plurality of legs completely through the adhesive layer and into the backing.  
   
   
       46 . The method of  claim 39 , wherein the step of selecting a face layer comprises selecting a stitching substrate comprising the plurality of fibers, stitch bonding the substrate using a shrinkable yarn, and shrinking the yarn to produce a gathered fabric structure to form the plurality of legs corresponding the undulating loops of the gathered fabric structure.  
   
   
       47 . The method of  claim 46 , wherein the adhesive layer is a shrinkable adhesive layer that is attached to the substrate before stitchbonding and shrinking.  
   
   
       48 . The method of  claim 39 , wherein the step of selecting a face layer comprises selecting a fibrous substrate containing the plurality of fibers, placing a shrinkable substrate in contact with the fibrous substrate bonding the fibrous substrate to the shrinkable substrate and shrinking the shrinkable layer to form a gathered fabric structure to form the plurality of legs corresponding the undulating loops of the gathered fabric structure.  
   
   
       49 . The method of  claim 48 , wherein the adhesive is a shrinkable adhesive placed in direct contact with the shrinkable adhesive before bonding and shrinking.  
   
   
       50 . The method of  claim 39 , wherein the face layer comprises a knit face layer and the method further comprises cutting the bottom surface of the face layer to produce the plurality of legs.  
   
   
       51 . The method of  claim 50 , further comprising stabilizing the top surface of the face layer before cutting the bottom surface.  
   
   
       52 . The method of  claim 39 , wherein the face layer comprises a woven face layer and the method further comprises cutting the bottom surface of the face layer to produce the plurality of legs.  
   
   
       53 . The method of  claim 52 , further comprising stabilizing the top surface of the face layer before cutting the bottom surface.  
   
   
       54 . The method of  claim 39 , further comprising embossing the composite with a 3-dimensional face texture.