Fabric-Faced Composites and Methods for Making Same

Abstract

The present invention is directed to multiple layer composites 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 bonded to an adhesive layer such that the adhesive layer penetrates into the face layer. The face layer can have legs extending there from, and such legs are anchored by the adhesive layer to provide stronger attachment between the adhesive layer and the face layer. A backing layer may also be provided in contact with the adhesive layer such that the adhesive layer also embeds into the backing layer, and the legs extending from the face layer may penetrate into the backing layer.

1 - 55 . (canceled) 
     
     
         56 . A composite comprising a fibrous face layer having a top surface and a bottom surface, an adhesive layer having a top surface and a bottom surface and a backing layer, wherein the bottom surface of the fibrous face layer faces the top of the adhesive layer and the bottom surface of the adhesive layer faces the backing layer, wherein the fibrous face layer comprises a gathered fabric forming a plurality of legs extending away from the top surface of the fibrous layer, said legs comprise undulated folds or gathers from the fibrous face layer, wherein the legs of the fibrous face layer are bonded to the adhesive layer and wherein the top surface of the fibrous face layer is substantially free of adhesive,
 wherein the adhesive layer is at least partially bonded to the backing layer.   
     
     
         57 . A composite comprising a fibrous face layer having a top surface and a bottom surface, an adhesive layer having a top surface and a bottom surface and a backing layer, wherein the bottom surface of the fibrous face layer faces the top of the adhesive layer and the bottom surface of the adhesive layer faces the backing layer, wherein the fibrous face layer comprises a knit or woven fabric forming a plurality of legs extending away from the top surface of the fibrous layer, said legs comprise pile loops of the knit or woven fabric, wherein the legs of the fibrous face layer are bonded to the adhesive layer and wherein the top surface of the fibrous face layer is substantially free of adhesive,
 wherein the adhesive layer is at least partially bonded to the backing layer.   
     
     
         58 . A composite comprising a fibrous face layer having a top surface and a bottom surface, an adhesive layer having a top surface and a bottom surface and a backing layer, wherein the bottom surface of the fibrous face layer faces the top of the adhesive layer and the bottom surface of the adhesive layer faces the backing layer, wherein the fibrous face layer comprises a cut, sanded, sheared or brushed woven or knit forming a plurality of legs extending away from the top surface of the fibrous layer, said legs are made from the cut, sanded, sheared or brushed portion of the fibrous face layer, wherein the legs of the fibrous face layer are bonded to the adhesive layer and wherein the top surface of the fibrous face layer is substantially free of adhesive,
 wherein the adhesive layer is at least partially bonded to the backing layer.   
     
     
         59 . The composite of  claim 56 , wherein the adhesive layer penetrates into the fibrous face layer by an application of pressure. 
     
     
         60 . The composite of  claim 57 , wherein the adhesive layer extends at least partially into the face layer by an application of pressure. 
     
     
         61 . The composite of  claim 58 , wherein the adhesive layer extends at least partially into the face layer by an application of pressure. 
     
     
         62 . The composite of  claim 56 , wherein a top portion of the fibrous face layer above the top of the adhesive layer has a thickness of about 0.5 mm to about 2.0 mm. 
     
     
         63 . The composite of  claim 56 , wherein a top portion of the fibrous face layer above the top of the adhesive layer has a basis weight of about 100 grams/m 2  to about 500 grams/m 2 . 
     
     
         64 . The composite of  claim 56  being embossable to form a three-dimensional textured product. 
     
     
         65 . The composite of  claim 56 , wherein the fibrous face layer comprises fibers of about 0.5 denier to about 5.0 deniers. 
     
     
         66 . The composite of  claim 56 , wherein the adhesive layer penetrates into about ¼ to about ¾ of the fibrous face layer. 
     
     
         67 . The composite of  claim 57 , wherein a top portion of the fibrous face layer above the top of the adhesive layer has a thickness of about 0.5 mm to about 2.0 mm. 
     
     
         68 . The composite of  claim 57 , wherein a top portion of the fibrous face layer above the top of the adhesive layer has a basis weight of about 100 grams/m 2  to about 500 grams/m 2 . 
     
     
         69 . The composite of  claim 57  being embossable to form a three-dimensional textured product. 
     
     
         70 . The composite of  claim 57 , wherein the fibrous face layer comprises fibers of about 0.5 denier to about 5.0 deniers. 
     
     
         71 . The composite of  claim 57 , wherein the adhesive layer penetrates into about ¼ to about ¾ of the fibrous face layer. 
     
     
         72 . The composite of  claim 58 , wherein a top portion of the fibrous face layer above the top of the adhesive layer has a thickness of about 0.5 mm to about 2.0 mm. 
     
     
         73 . The composite of  claim 58 , wherein a top portion of the fibrous face layer above the top of the adhesive layer has a basis weight of about 100 grams/m 2  to about 500 grams/m 2 . 
     
     
         74 . The composite of  claim 58  being embossable to form a three-dimensional textured product. 
     
     
         75 . The composite of  claim 58 , wherein the fibrous face layer comprises fibers of about 0.5 denier to about 5.0 deniers.